Guide to Essential Maintenance and Upgrades for Automated Systems

Don’t let outdated or poorly maintained automated systems slow you down. By implementing a strategic combination of preventive maintenance and targeted upgrades, you can significantly extend the lifespan of your automation equipment, optimize performance, and keep your production lines running smoothly. 

This guide equips you with the knowledge you need to develop an effective automated system maintenance plan, including essential preventive maintenance checklists. We’ll also explore different automation upgrade options to help you choose the right solutions to address your specific needs and keep your technology relevant in today’s ever-evolving manufacturing landscape.

Ultimately, this proactive approach will help you maximize your return on investment (ROI) and ensure your automated systems continue to be a competitive advantage for your business.

The Importance of Maintenance for Automated Systems

Skimp on maintenance for your automated systems at your peril. A well-executed preventive maintenance plan is an investment that protects your bottom line. ​​It’s understandable that businesses face time pressures and the need to maximize production.

Neglecting preventive maintenance is a false economy. The short-term gains from uninterrupted output are quickly dwarfed by the devastating consequences of a breakdown.

By proactively addressing potential issues, you can ensure the safe operation of your equipment, minimize downtime that disrupts production schedules, and extend the lifespan of your automated systems. This translates to significant cost savings in the long run as you avoid expensive repairs and replacements.

Your manufacturing automation integrator should provide comprehensive manuals, training, and ongoing support to empower you to maintain your equipment effectively.

By following your integrator’s instructions and sticking to a regular maintenance schedule, you’ll optimize the performance of your automated systems and keep your entire production line running smoothly.

Related Reading: The Future of Robotics in Manufacturing

Designated Automation Maintenance Team

Investing in automated systems is a significant step towards increased productivity and efficiency in your manufacturing operations. To ensure you continue to reap the benefits of your investment for years to come, assembling a designated maintenance crew with the proper training and expertise in your automated systems is crucial. 

This team, which can be comprised entirely of your in-house staff or a combination of your internal team and specialists from your automation integrator, plays a vital role in keeping your automated systems running smoothly and safely.

By allowing a dedicated crew to take ownership of maintenance tasks, you can avoid costly downtime, extend the lifespan of your equipment, and optimize overall production output.

Key Responsibilities of Your Maintenance Crew

A competent automation maintenance team takes a proactive approach to safeguarding the performance and longevity of your automated systems. Their responsibilities encompass several key areas.

Preventive Maintenance Scheduling

The automation maintenance team leads the development and enforcement of a consistent and methodical preventive maintenance schedule. This approach ensures potential issues are identified and resolved early on before they can snowball into major problems that disrupt production. 

Companies can minimize unexpected downtime and associated costs by adhering to a preventative maintenance schedule. Regular preventive maintenance also helps to extend the lifespan of automated equipment, reducing the need for costly replacements and upgrades in the long run.

Clear Communication and Coordination

The maintenance team works closely with production teams to schedule maintenance during periods of minimal disruption. They clearly communicate the planned maintenance schedule to all relevant stakeholders, including management, production personnel, and any other teams that might be affected.

This transparency ensures everyone is on the same page and allows adjustments to be made as needed. Open communication also helps build buy-in for the importance of preventive maintenance throughout the organization.

Related Reading: Getting Your Workforce on Board for Change 

Skilled Troubleshooting and Repairs

Your automation maintenance team is your first defense against production slowdowns and downtime. They have the expertise to quickly diagnose issues, perform repairs, and replace faulty components within your automated systems. Their proactive approach to scheduled maintenance, as outlined in your integrator’s recommendations, minimizes the need for emergency repairs.

However, their troubleshooting skills go beyond routine maintenance. They can swiftly address unexpected problems that arise during operation, ensuring minimal disruption to your production schedule. This ability to identify and resolve issues promptly helps your business avoid the domino effect of equipment failure, saving you time and money.

Proactive Part Management and Stocking

Anticipating part lifecycles and stocking essential spares is vital for minimizing downtime. By implementing a thorough part management strategy, your automation maintenance team will maintain a well-organized inventory of replacement parts, including common wear items and long-lead components.

Inventory management ensures your team has the necessary parts on hand to address maintenance needs and repairs swiftly, minimizing production delays. They’ll collaborate with suppliers and track purchase orders to ensure parts are readily available when needed. 

Developing strong relationships with reliable vendors can expedite the procurement process in the event of unexpected malfunctions or emergencies.

Your maintenance team will diligently monitor the lifespans of critical parts within your automated systems, allowing for maintenance and replacement before failures occur, ensuring your production line continues to operate smoothly. 

Related Reading: Cobots vs. Robots: What’s Right For You?

Vigilant Equipment Monitoring and Software Updates

Your automation maintenance team plays a crucial role in safeguarding the optimal performance and longevity of your automated systems by meticulously monitoring equipment health. They’ll inspect and maintain physical gauges, HMIs, and other vital monitoring devices to ensure reliable readings.

This data is key for early detection of potential issues, allowing the team to address problems before they escalate into costly breakdowns. They’ll also diligently track software and firmware updates for all interconnected equipment, promptly applying patches and security updates. 

Maintaining your software at the latest version is crucial for performance and security, ensuring compatibility and minimizing vulnerabilities.

Proactive Troubleshooting

Modern automation systems generate valuable data. Proactive troubleshooting uses this data to go beyond basic monitoring, assisting your maintenance team in several ways. Firstly, they can analyze trends and patterns to pinpoint the root causes of potential malfunctions, not just the symptoms. This allows them to address issues before they cause costly downtime, often without even needing to halt production. 

Proactive troubleshooting also enables the team to predict and plan maintenance by scheduling necessary repairs or adjustments during planned downtime or production lulls. And, of course, many troubleshooting tasks can be performed remotely, saving time and reducing onsite disruptions. 

Data-driven insights from proactive troubleshooting can also enhance communication about issues between maintenance and production teams. Proactive troubleshooting delivers a powerful contrast to the reactive approach:

• Controlled vs. Chaotic: Take charge of troubleshooting instead of scrambling when a machine unexpectedly fails.
• Predictable Costs: Budget-friendly maintenance as opposed to emergency repairs.
• Maximized Uptime: Production continues with minimal interruptions.

Continuous Training and Knowledge Transfer

A strong preventative maintenance plan recognizes that expertise is key. Your automation maintenance team should uphold the highest standards with a focus on continuous learning. However, it’s essential to clarify that access to knowledge resources does not equate to immediate maintenance competency.

Prioritize comprehensive training programs to ensure both new and experienced team members possess the necessary skills and understanding. This means developing and maintaining training materials, including clear and concise manuals, video tutorials, and interactive simulations.

While high-quality materials are essential, they are a tool to be used after proper training. Preventative maintenance discipline includes restricting maintenance tasks to those who have demonstrated proficiency through your training programs.

This ongoing process allows team members to independently troubleshoot and address common maintenance issues, reducing reliance on external support and ensuring your production line operates smoothly.

Adapting to Change

When it comes to industrial automation, it’s crucial to stay ahead of the curve. When upgrades or updates are implemented, your maintenance team will incorporate new procedures and best practices into their training curriculum.

This adaptability ensures your team can expertly manage the latest technologies and maintain optimal system performance, maximizing the return on your investment in automation.

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System Maintenance Checklist: Your Roadmap to Optimal Automation

A well-structured checklist is the foundation of an effective maintenance strategy for ensuring your custom automated systems operate at peak performance. Investing time to develop a comprehensive checklist specific to your equipment will help streamline maintenance procedures, minimize unscheduled downtime, and extend the lifespan of your valuable automation investments. 

When you partner with a quality integrator, you should receive extensive training in proper maintenance procedures for your specific machinery. Your equipment should have features designed to assist your maintenance crew, providing clear insights into operating status and streamlining upkeep tasks. 

To maximize reliability and minimize downtime, it’s essential to conduct thorough maintenance checks before operation, after repairs, during scheduled maintenance periods, and following any software or hardware upgrades.

Of course, each custom system requires a unique approach. Let’s start with the following general automation maintenance checklist as a foundation.

Visual Inspection: Safeguarding Your System’s Integrity

A thorough visual inspection may seem basic, but it’s a crucial first step in your preventive maintenance routine for automated systems. By taking a close look at your machinery, you can proactively identify potential problems, ensuring your equipment remains in optimal working condition.

• Preventative Maintenance: Regular visual inspections allow you to catch potential issues early before they snowball into major breakdowns or malfunctions.

• Reference Original Designs: Compare the physical structure of your automated system to the original blueprints and design documents to ensure all components remain correctly installed and configured, as any discrepancies could lead to performance issues.

• Identify Wear and Tear: Carefully examine all exposed areas of the machinery for signs of wear, damage, or debris buildup. Promptly addressing these concerns helps preserve your equipment’s lifespan and avoid costly repairs down the line.

Proper Cleaning: Safeguarding System Performance

Always use cleaning products specifically approved for industrial automation equipment. Incorrect cleaning agents can damage sensitive components, leading to malfunctions or reduced system lifespan. Regular cleaning removes dust, debris, and contaminants that can interfere with sensors, obstruct moving parts, or contribute to overheating.

Refer to your integrator’s maintenance manual for a list of approved cleaning solutions and procedures.

Software Updates: Safeguarding Security and Functionality

In the world of industrial automation, software updates play a vital role in keeping your automated systems running smoothly and securely. Neglecting updates can leave your system vulnerable to cybersecurity threats, performance hiccups, and compatibility issues. Make software maintenance a priority in your preventive maintenance plan to safeguard your investment.

• Stay Up-to-Date: Regularly check for security patches and software updates for your automated system’s operating system and related software. These updates often include critical fixes for vulnerabilities and improve overall performance.

• Thorough Review: Before installing any update, carefully review its release notes. Document the changes and their potential impact on your system.

• Test and Verify: After applying updates, rigorously test any related functions to ensure compatibility and catch any issues stemming from the changes.

• Automation Integrator Support: Your integrator should provide guidance or offer support with updates as part of your contract.

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Data Logs: Your Troubleshooting Goldmine

Your automated system’s data logs contain a wealth of information that can be used for troubleshooting and system optimization. By diligently analyzing data logs as part of your preventive maintenance routine, you can identify potential issues early on, optimize processes, and improve the overall efficiency of your automated systems.

• Analyze Data: Regularly review your automated system’s data logs for error messages, warnings, and any unusual patterns in recorded data. These can often provide early indicators of potential problems.

• Investigate Thoroughly: When anomalies are detected, look deeper to pinpoint the root cause of the issue. Thorough troubleshooting is essential in preventing recurring problems.

• Document and Prioritize: Maintain clear records of any errors, warnings, or identified issues. Prioritize them based on severity and their potential impact on production.

• Take Corrective Action: Target critical issues for immediate repair or address them during scheduled maintenance.

• Visualization Tools: Explore if your system or third-party tools offer data visualization for easier analysis.

• Integrator Support: You may be able to work with your integrator to set up alerts for critical errors.

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Emergency Procedures: Protecting Personnel and Equipment

Safety is paramount in automated systems. Regularly testing emergency stop functionality and power failure procedures is critical to minimize the risk of injury or equipment damage in unexpected situations.

• Emergency Stop (E-stop) Testing: Verify that hitting the e-stop button immediately halts all machine movement and triggers any necessary safety protocols.

• Power Loss Simulation: Upon a power loss, ensure your system follows a controlled shutdown sequence to prevent abrupt stops that can damage components.

• Safe Reactivation: Confirm that your automated system follows the designated restart procedures upon power restoration, prioritizing safety before resuming normal operation.

Important Note: Always refer to your integrator’s maintenance guide for specific testing procedures and safety precautions.

Performance Testing and Quality Control

Rigorous performance testing and meticulous quality control are essential components of your preventive maintenance plan. These practices ensure your automated systems consistently meet production targets and deliver high-quality products. By prioritizing these checks, you’ll optimize efficiency, minimize waste, and safeguard your brand reputation.

• Verify System Performance: Regularly run production tests with a representative sample of your SKUs. Compare the output and performance metrics against your established benchmarks. Utilize both internal data logging and independent measurement tools for comprehensive validation. This process helps identify any deviations from expected performance for early intervention.

• Quality Assurance: Closely inspect product samples for any defects, inconsistencies, or deviations from quality standards. Thorough quality control is essential to ensure your automated system consistently produces top-notch output that meets customer expectations.

Data Integrity: Ensuring Accuracy and Reliability

Accurate and reliable data is the cornerstone of effective decision-making in the world of industrial automation. By meticulously validating the data generated by your automated systems, you ensure you’re working with a trustworthy picture of your production processes. 

• Validate Data Accuracy: Cross-check the data recorded in your automated system’s logs against independent measurements or data collected by external equipment. This validation process ensures your internal data accurately reflects real-world performance, speed, and quality metrics. 

• Frequency: Determine how often these checks are necessary based on your system and production sensitivity.

• Automation Tools: If available, consider using data validation tools to streamline this process.

Repair and Replacement: Restoring Optimal Performance

Proactively addressing issues through repair and timely replacement of worn parts is essential for keeping your automated systems running smoothly and minimizing downtime.

• Fix Damage: Address any identified damage promptly to prevent further complications.

• Replace Worn Parts: Replace components showing signs of wear and tear according to the manufacturer’s recommended lifespan or as observed during inspections.

• Optimize and Service: Use repair opportunities to fine-tune settings, improve performance, or carry out additional servicing.

• Communicate Upwards: Report any major repairs or recurring issues to relevant stakeholders to facilitate further investigation or potential upgrades.

Documentation: Maintaining Knowledge and Consistency

Meticulous documentation is vital for ensuring the long-term maintainability of your automated systems. Up-to-date manuals and guides streamline maintenance tasks, support efficient troubleshooting, and encourage smooth knowledge transfer among your team.

• Verify Updates: Cross-reference your training and operator manuals with the latest system updates, software changes, or hardware modifications.

• Update Thoroughly: Amend your documentation to reflect any changes, ensuring instructions remain accurate and up-to-date.

• Style Consistency: Adhere to a consistent internal style guide for all documentation, promoting clarity and ease of use.

Lubrication: Safeguarding Smooth Operation

Proper lubrication is critical for reducing friction, minimizing wear, and extending the lifespan of your automated system’s moving components.

• Follow the Guidelines: Adhere strictly to the manufacturer’s lubrication specifications, using approved lubricants and following recommended schedules.

• Target Key Areas: Focus on greasing or oiling all linear and rotational motion components as outlined in your maintenance guide.

Monitoring: Detecting Early Signs of Wear

Regular monitoring helps you catch potential problems before they cause major breakdowns or downtime.

• Backlash and Concentricity: Check for excessive backlash (looseness) or lost concentricity (misalignment) in your linear and rotational components. These can indicate wear or damage.

• Conveyor Inspection: Thoroughly examine your conveyor belts for signs of wear, fraying, or misalignment. Address any issues promptly to prevent malfunctions.

Inventory Management: Ensuring Part Availability

Proactive inventory management ensures you always have essential spare parts on hand for timely replacements.

• Stock Critical Components: Maintain an adequate stock of wear components and any parts with known long lead times.

• Reorder Strategically: Establish reorder thresholds based on usage patterns and manufacturer-recommended lifespans to prevent stockouts.

• Manage Obsolescence and Sourcing: Stay informed about potential part discontinuations and have approved substitutions identified. Maintain relationships with multiple vendors for critical parts, reducing the risk of supplier issues.

Evolve Your Automation: The Power of Strategic Upgrades

Don’t let outdated technology hinder your progress. Upgrading your existing automated system is a strategic investment that delivers multiple benefits to your bottom line. You can unlock significant performance enhancements by integrating your current system with the latest software and firmware. 

Optimized algorithms, streamlined processes, and improved control over your production line all contribute to increased efficiency and output.

In today’s manufacturing environment, staying ahead of the curve is crucial. Operating system upgrades can equip your system with new functionalities, potentially opening doors to new production possibilities or integrating seamlessly with cutting-edge technologies.

Nowadays, many upgrades can be implemented remotely by your trusted automation integrator, minimizing downtime and disruption to your operations. This ensures a smooth upgrade process that maximizes the return on your investment.

Modernizing your automated system’s operating system and firmware can boost efficiency, enhance control, and unlock new capabilities. Benefits include:

• Improved Performance: Optimized software often results in faster processing, smoother operation, and increased overall system efficiency.

• Enhanced Functionality: Updates can introduce new features, streamline processes, and provide greater flexibility in how you manage your automated system.

• Remote Support: Your automation integrator can implement many upgrades remotely, ensuring a smooth process and minimizing downtime.

• Self-Programming Potential: Partnering with the right integrator can provide access to the training needed to self-program specific improvements, increasing your in-house capabilities and autonomy.

Hardware Upgrades: Boosting Capacity and Adaptability

Investing in hardware upgrades is a cost-effective way to enhance the performance and capabilities of your existing automated system. A skilled integrator will design your custom solution with upgrade potential in mind, allowing for improvements such as:

• Strengthened Structure: Replacing components with more robust materials can extend the system lifespan and increase load capacity.

• Advanced Hardware: Upgrading embedded hardware, sensors, and controllers can optimize performance and enhance functionality.

• Peripherals and Expansion: Adding peripherals like cameras, safety systems, or additional or upgraded control devices can expand your system’s capabilities and versatility.

Secondary Processing: Expanding Your Automation Footprint

Seamlessly extending your existing automated system opens up possibilities for streamlining your production line and maximizing your investment value. Consider integrating:

• Machine Tending Systems: Automate loading and unloading processes to increase throughput and eliminate bottlenecks.

• Pick and Place Systems: Add precision robotics for sorting, assembly, or packaging tasks.

• Packaging and Palletizing Systems: Automate end-of-line processes, reducing labor costs and increasing accuracy.

Related Reading: Choosing Your First Automation Project 

Partnering with Excellence: The Key to Optimized Automation

Choosing the right custom machine integrator is the foundation of a successful automation project and sets the stage for long-term success. A skilled integrator can minimize your maintenance burdens and maximize the return on your automation investment. Here’s why:

• Precision from the Start: Well-designed and expertly engineered systems inherently require less maintenance and offer a longer, more reliable lifespan.

• Streamlined Processes: A vertically integrated integrator handles all aspects of design and manufacturing in-house, promoting seamless communication, efficient workflows, and superior quality control.

• Self-Sufficiency and Support: The best integrators prioritize your long-term success. They’ll provide comprehensive training, empowering your team to confidently manage your machinery. Additionally, open communication channels ensure you have expert support for any future needs, repairs, or expansions.

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to Your Industrial Machine Design Proposal

Safeguard Your Investment with a Maintenance Contract

Maximize the lifespan and ROI of your automated systems with a tailored maintenance contract. By partnering with an integrator offering comprehensive support plans, you can enjoy cost savings, rapid support, streamlined upgrades, and the peace of mind that comes from expert care.

Cost Savings

A preventative maintenance contract goes beyond basic repairs. It’s a strategic investment designed to minimize your long-term costs and maximize the efficiency of your automated systems.

• Reduced Repair Costs: Benefit from discounted labor, engineering, and parts compared to ad-hoc repairs.

• Proactive Approach: Preventative maintenance minimizes the likelihood of breakdowns, extending machinery lifespan.

Swift Support and Troubleshooting

When unexpected issues arise, minimizing downtime is crucial. A comprehensive maintenance contract provides multiple layers of support to ensure your operations get back up and running swiftly.

• Instantaneous Remote Access: Get immediate assistance from experts who can remotely troubleshoot issues.

• Onsite Support When Needed: Provisions for prompt onsite inspection and repair when necessary.

Simplified Upgrades and Maintenance

Managing upgrades and scheduling maintenance checks can feel like an added burden. A maintenance contract tackles these tasks for you, providing a simplified and efficient approach.

• Automatic Updates: Receive software and firmware upgrades seamlessly through the IIOT network.

• Managed Scheduling: Choose from flexible maintenance plans (annual, semi-annual, etc.) to best suit your production needs.

Continuity and Expertise

Your automated system is a complex piece of equipment. A maintenance contract ensures the team who understands its intricacies is always on hand to address your needs.

• The Team That Knows Your System: Maintenance is handled by the same experts who built your machinery, ensuring deep understanding and efficient resolutions.

Remote Diagnostics and Optimization

Modern automated systems generate valuable data. With a maintenance contract, a team of experts uses this data to proactively identify areas for improvement and keep your system operating at peak performance.

• Proactive Monitoring: Our team remotely monitors key performance metrics, catching potential problems early on.

• Data-Driven Insights: Receive reports on trends, potential issues, and recommendations for maximizing your system’s performance.

Related Reading: Automation Technology ROI

Maximize Automation ROI: Invest in Expert Maintenance and Strategic Upgrades

You’ve invested in cutting-edge automated systems to streamline your production processes. Don’t let outdated equipment, unexpected breakdowns, or missed optimization opportunities erode your ROI.

Proactive maintenance, strategic upgrades, and a tailored maintenance contract are the keys to unlocking the full potential of your automated systems. Partnering with a skilled integrator like DEVELOP LLC empowers you to minimize downtime, extend equipment lifespan, and stay ahead of the curve in the ever-evolving world of industrial automation.

Picture a production line where breakdowns are rare, upgrades are seamless, and your systems consistently deliver peak performance. With a commitment to expert maintenance, you can achieve this level of efficiency and optimize your manufacturing output.

At DEVELOP LLC, we’re committed to providing the solutions you need to achieve lasting success with automation. Let’s start a conversation about your specific needs and goals. 

Tell us more about your project, schedule a virtual meeting, or call (262)-622-6104 to discuss how we can help you plan maintenance and upgrades for your automated systems. 

Our engineering specialists, manufacturing experts, and automation project managers are ready to answer your questions and guide you toward optimized automation solutions.

Let’s Optimize Your Automation Journey!

 

About the Author:

Sean McKittrick, as Project Program Coordinator at DEVELOP LLC, brings a multifaceted background from Knox College. McKittrick’s first year at DEVELOP LLC has been marked by significant team growth and zero turnover, showcasing his ability to build a collaborative and effective work environment. His experience spans quality management in healthcare software to managing production for a million pounds of material monthly, highlighting his diverse expertise in project coordination and manufacturing excellence.