MaintenancePM - Preventive Maintenance System
Purpose: Protect capital equipment investment through systematic preventive maintenance.
When to Activate
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"What's the PM schedule for NLX2500?"
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"Create maintenance checklist"
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"What's due for service?"
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"TPM checklist for Swiss machines"
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"Maintenance history for [machine]"
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"PM planning"
Maintenance Philosophy
Total Productive Maintenance (TPM)
Level Responsibility Frequency Examples
Operator Daily/Shift Every shift Cleaning, lubrication, visual checks
Technician Weekly/Monthly Scheduled Filter changes, calibration, adjustments
Specialist Quarterly/Annual Planned Major service, rebuilds, alignments
OEM As required Scheduled Warranty service, major repairs
DMG MORI Machines
Daily Checks (Operator - Every Shift)
Daily PM Checklist - DMG MORI
Machine: _____________ Date: _________ Operator: _________
Start of Shift
| Check | OK | Issue | Notes |
|---|---|---|---|
| Coolant level | ☐ | ☐ | |
| Coolant concentration (refractometer) | ☐ | ☐ | Target: ___% |
| Hydraulic oil level | ☐ | ☐ | |
| Way lube level | ☐ | ☐ | |
| Air pressure (6 bar min) | ☐ | ☐ | |
| Chip conveyor clear | ☐ | ☐ | |
| Guards/doors function | ☐ | ☐ | |
| No unusual noises | ☐ | ☐ | |
| Spindle warm-up complete | ☐ | ☐ |
End of Shift
| Task | Done | Notes |
|---|---|---|
| Clean machine exterior | ☐ | |
| Remove chips from work area | ☐ | |
| Wipe down way covers | ☐ | |
| Return tools to crib | ☐ | |
| Report any issues | ☐ |
Signature: _____________
Weekly PM - DMG MORI Mills (NMV3000, DMU50, NHX500)
Weekly PM - DMG MORI 5-Axis Mill
Machine: _____________ Week: _________ Tech: _________
| Task | Done | Reading/Notes |
|---|---|---|
| Check spindle runout | ☐ | TIR: ___μm (max 5μm) |
| Inspect tool changer | ☐ | |
| Clean coolant tank strainer | ☐ | |
| Check way lube distribution | ☐ | |
| Inspect pallet changer (if equipped) | ☐ | |
| Verify probe calibration | ☐ | |
| Check air dryer/filter | ☐ | |
| Inspect chip conveyor belt | ☐ | |
| Check hydraulic filter indicator | ☐ | |
| Clean control cabinet filter | ☐ |
Pallet System (NMV3000/DMU50)
| Task | Done | Notes |
|---|---|---|
| Check pallet locating surfaces | ☐ | |
| Verify pallet clamping | ☐ | |
| Lubricate pallet transfer | ☐ |
Issues Found: ___________________________________ Action Taken: ___________________________________
Weekly PM - DMG MORI Lathes (NLX2500, ALX2000)
Weekly PM - DMG MORI Turning Centre
Machine: _____________ Week: _________ Tech: _________
| Task | Done | Reading/Notes |
|---|---|---|
| Check chuck clamping pressure | ☐ | Main: ___bar Sub: ___bar |
| Inspect turret indexing | ☐ | |
| Check tailstock alignment (if used) | ☐ | |
| Verify bar feeder operation | ☐ | |
| Clean chip conveyor | ☐ | |
| Check coolant nozzle positioning | ☐ | |
| Inspect sub-spindle (NLX2500) | ☐ | |
| Verify tool sensor operation | ☐ | |
| Check hydraulic pressure | ☐ | ___bar |
| Clean/replace coolant filter | ☐ |
Live Tooling Check:
| Task | Done | Notes |
|---|---|---|
| Check live tool runout | ☐ | TIR: ___μm |
| Lubricate live tool holders | ☐ | |
| Verify C-axis indexing | ☐ |
Monthly PM - All DMG MORI
Monthly PM - DMG MORI
Machine: _____________ Month: _________ Tech: _________
Lubrication
| Task | Done | Notes |
|---|---|---|
| Check/top up way lube reservoir | ☐ | Level: ___% |
| Verify lube pump operation | ☐ | |
| Grease linear guide wipers | ☐ | |
| Lubricate ball screws (if manual) | ☐ |
Hydraulics
| Task | Done | Notes |
|---|---|---|
| Check hydraulic oil level | ☐ | |
| Inspect for leaks | ☐ | |
| Check pressure gauge accuracy | ☐ |
Coolant System
| Task | Done | Notes |
|---|---|---|
| Clean coolant tank thoroughly | ☐ | |
| Replace coolant filters | ☐ | |
| Check pump operation | ☐ | |
| Verify through-spindle pressure | ☐ | ___bar |
Electrical
| Task | Done | Notes |
|---|---|---|
| Clean control cabinet (air blow) | ☐ | |
| Check fan operation | ☐ | |
| Inspect cables for damage | ☐ |
Accuracy Check
| Measurement | Spec | Actual | Pass |
|---|---|---|---|
| Spindle runout | <5μm | ☐ | |
| Axis backlash X | <5μm | ☐ | |
| Axis backlash Y | <5μm | ☐ | |
| Axis backlash Z | <5μm | ☐ |
Annual PM - DMG MORI
Task Interval Last Done Next Due Notes
Ball screw inspection Annual
OEM or trained tech
Spindle bearing check Annual
Vibration analysis
Geometric alignment Annual
Laser or ballbar
Hydraulic oil change Annual/2000hr
Way lube oil change Annual
Coolant full change 6 months
Encoder battery 2 years
CRITICAL
Control backup Annual
HARDINGE Precision Lathe
Daily - Operator
Daily PM - HARDINGE
| Check | OK | Issue |
|---|---|---|
| Spindle warm-up (20 min) | ☐ | ☐ |
| Collet/chuck cleanliness | ☐ | ☐ |
| Coolant level and temp | ☐ | ☐ |
| Air pressure | ☐ | ☐ |
| No unusual vibration | ☐ | ☐ |
Weekly - Precision Checks
Weekly PM - HARDINGE
| Task | Done | Reading |
|---|---|---|
| Spindle runout check | ☐ | TIR: ___μm (max 2μm) |
| Temperature log start/end | ☐ | Start: ___°C End: ___°C |
| Collet concentricity | ☐ | TIR: ___μm |
| Sub-spindle alignment | ☐ |
CITIZEN Swiss Machines
Daily - Operator
Daily PM - CITIZEN Swiss
Machine: [ ] Laser Head [ ] LFV Date: _________ Operator: _________
| Check | OK | Issue | Notes |
|---|---|---|---|
| Oil level | ☐ | ☐ | |
| Oil temperature | ☐ | ☐ | Target: 25-30°C |
| Guide bushing condition | ☐ | ☐ | |
| Bar stock quality | ☐ | ☐ | |
| Chip evacuation | ☐ | ☐ | |
| Air pressure (5 bar) | ☐ | ☐ | |
| Mist collector filter | ☐ | ☐ | |
| Part catcher clear | ☐ | ☐ |
Weekly - Swiss Specific
Weekly PM - CITIZEN Swiss
| Task | Done | Notes |
|---|---|---|
| Clean guide bushing area | ☐ | |
| Check guide bushing wear | ☐ | |
| Inspect collet condition | ☐ | |
| Verify gang tool alignment | ☐ | |
| Check back-working tools | ☐ | |
| Clean oil filter | ☐ | |
| Verify LFV operation (if equipped) | ☐ | |
| Check laser alignment (if equipped) | ☐ | |
| Inspect bar feeder | ☐ | |
| Check sub-spindle pickup | ☐ |
Oil Analysis (Monthly):
| Parameter | Spec | Actual | Pass |
|---|---|---|---|
| Contamination | <NAS 8 | ☐ | |
| Water content | <0.1% | ☐ | |
| Viscosity | ±10% | ☐ |
Monthly - CITIZEN
Task Done Notes
Full oil tank clean ☐
Replace oil filter element ☐
Guide bushing replacement (if worn) ☐
Check Z-axis gibs ☐
Verify spindle accuracy ☐
Clean electrical cabinet ☐
MITSUBISHI EDM
Daily - Wire EDM
Daily PM - MITSUBISHI Wire EDM
Date: _________ Operator: _________
| Check | OK | Issue |
|---|---|---|
| Dielectric level | ☐ | ☐ |
| Dielectric conductivity | ☐ | ☐ |
| Wire path clear | ☐ | ☐ |
| Filter pressure | ☐ | ☐ |
| Wire guides condition | ☐ | ☐ |
| Flushing nozzles clear | ☐ | ☐ |
| Wire tension | ☐ | ☐ |
| Auto-threader operation | ☐ | ☐ |
Daily - Spark EDM
Daily PM - MITSUBISHI Spark EDM
Date: _________ Operator: _________
| Check | OK | Issue |
|---|---|---|
| Dielectric level | ☐ | ☐ |
| Dielectric clarity | ☐ | ☐ |
| Filter condition | ☐ | ☐ |
| Electrode holder clean | ☐ | ☐ |
| Flush pump operation | ☐ | ☐ |
| Fire suppression OK | ☐ | ☐ |
Weekly - Both EDM Types
Task Done Notes
Check dielectric conductivity ☐ Target: 20-40μS
Clean/replace filters ☐
Inspect wire guides (wire) ☐
Check AWT roller condition (wire) ☐
Verify axis accuracy ☐
Clean work tank ☐
Check resin condition ☐
Monthly - EDM
Task Done Notes
Full dielectric change ☐ If contaminated
Replace deionizing resin ☐ When conductivity rises
Wire guide replacement ☐ Every 200-400 hrs
Power feed contact check ☐
Geometric accuracy check ☐
Haas Fast Response Cell
Daily - Operator
Daily PM - Haas
Machine: [ ] Mini Mill [ ] Tool Room Lathe
| Check | OK | Issue |
|---|---|---|
| Coolant level | ☐ | ☐ |
| Way lube level | ☐ | ☐ |
| Chip tray clear | ☐ | ☐ |
| Air pressure | ☐ | ☐ |
| Tool changer cycle | ☐ | ☐ |
| Spindle warm-up | ☐ | ☐ |
Weekly
Task Done Notes
Check spindle runout ☐
Verify tool changer alignment ☐
Clean coolant tank ☐
Check way covers ☐
Grease as required ☐
Maintenance Schedule Summary
Daily (Every Shift)
Machine Key Checks
All Fluid levels, air pressure, visual inspection
Mills Spindle warm-up, tool changer
Lathes Chuck pressure, bar feeder
Swiss Oil temp, guide bushing
EDM Dielectric level/conductivity
Weekly
Machine Key Tasks
All Accuracy checks, filter inspection
Mills Pallet system, probe calibration
Lathes Turret, live tooling
Swiss Guide bushing wear, oil filter
EDM Wire guides, filter change
Monthly
Machine Key Tasks
All Full cleaning, lubrication top-up
Mills Coolant change, accuracy verification
Lathes Hydraulic check, tailstock alignment
Swiss Oil tank clean, full inspection
EDM Resin check, geometric accuracy
Quarterly
Machine Key Tasks
All Major filter replacements
Mills Ballbar test
Lathes Spindle bearing analysis
Swiss OEM service items
EDM Full calibration
Annual
Machine Key Tasks
All Full OEM service, geometry check, major PM
All Backup all programs and parameters
All Hydraulic/lube oil change
Maintenance Log Template
Maintenance Log
Machine: _____________ Machine ID: ___________
| Date | Type | Hours | Description | Parts Used | Tech | Time |
|---|---|---|---|---|---|---|
| PM | ||||||
| Repair | ||||||
| PM |
Spare Parts Stock
Critical Spares (Keep on-site)
Machine Item Qty Lead Time Supplier
All Coolant filters 10 2 days
All Way lube filters 5 2 days
Swiss Guide bushings (common sizes) 5 ea 5 days
Swiss Collets 3 ea 3 days
EDM Wire guides 2 sets 5 days
EDM Resin 1 unit 3 days
EDM Filters 10 2 days
All Encoder batteries 2 3 days CRITICAL
Order Lead Times
Supplier Type Typical Lead
DMG MORI Spare parts 3-10 days
CITIZEN Spare parts 5-14 days
MITSUBISHI EDM parts 3-7 days
Haas Spare parts 3-7 days
Downtime Tracking
Downtime Log - [Month]
| Date | Machine | Start | End | Hours | Cause | Action | Category |
|---|---|---|---|---|---|---|---|
| PM/Breakdown/Setup |
Monthly Summary
| Category | Hours | % of Total |
|---|---|---|
| Planned PM | ||
| Breakdown | ||
| Waiting Parts | ||
| Other | ||
| Total |
Machine Availability
| Machine | Available Hrs | Downtime | Availability % |
|---|---|---|---|
Target: >95% Availability
Integration
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PlantCapability: Factor maintenance windows into capacity
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SkillsMatrix: Who is trained for which PM tasks
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TribalKnowledge: Capture maintenance tips and tricks
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OEETracker: Availability component of OEE