The plant manager came onboard three months ago and just hired you. During the interview, he seemed interested in your troubleshooting abilities. Your first assignment is why.
A few years ago, the plant installed a custom-built manufacturing line that is complex. Among other things, it includes several 3D printers. The line is considered critical, but as the plant manager pointed out, “They are always fixing something. If it’s not a bearing that went bad, it’s a motor. Or some electronics gizmo.”
The plant manager also told you that he personally reviewed the maintenance procedures and records against the manufacturer’s recommended maintenance found no deficiencies. How might you provide the solution?
Troubleshoot the maintenance and repair practices, not just the equipment. For example, bearings are failing. So, suspect incompatible lubricants and/or poor lubrication practices. Clear this up, and you’ll probably also reduce motor failure rates. You’ll need a lubrication expert to review the lubrication program in depth.
Go through the repair records and compile a chart of failure modes by frequency. Contact the manufacturer about reviewing this and recommending revisions to the maintenance practices.
Failures of electronics, bearings, and motors may have a common cause; the most likely candidate is improper bonding. This is often an area of confusion. Instead of having a low impedance path back to the source, there’s a hodgepodge of impedances in the way. Significant current thus flows through equipment.