How often should I replace parts on my production line machines?

An efficient production line is one that runs smoothly, day in and day out, maintaining optimum productivity. This is by no means easy to achieve. The key is to do everything you can to ensure that every machine that forms the line is well-kept and working correctly.

However, as your machines are used continually, it is only natural for wear and tear to occur. Eventually, this may lead to actual damage to your equipment – which can go on to halt your production, lead to error and product waste, and bring unwanted downtime to your operations. This is a scenario that no manufacturer wants to find themselves in.

The best way to reduce the risk of damage across your machinery is to maintain it frequently. Part of this maintenance should include replacing components in your equipment when those parts become damaged and broken. By doing so, you will be able to keep the entire system working correctly – and regular replacements should help you to keep on top of any breakages before they happen.

This begs the question ‘how often should I replace parts in my production line?’. In this guide, we have outlined how frequently you may expect to replace parts to maximise results and minimise disruption across your whole plant.

• How often to replace machine parts
• How often to check your machinery
• Building a stock of spare parts
• The benefits of maintained equipment

How often to replace machine parts

While regular maintenance of your machinery is always encouraged, the exact timeframes for replacing parts will vary from machine to machine and factory to factory. Factors like how often you use each machine and the substances you use them for will impact the level of wear and tear your equipment is subject to, and how rapidly this will build up. Issues like user error, plant environment, contamination and product flow may also play a role in how quickly repairs are needed.

Due to the many contributing aspects, it is impossible to designate a set date for when you should replace parts in your machine. The only certainty is that you must replace parts as soon as you become aware there is a break or issue with your machine. By taking swift action, you will be able to reduce the negative consequences for your production line.

While it is tempting to hold back on expenditure, if you neglect the replacement of parts until the problems have started to create havoc in your operations, it is simply too late. You would be risking health and safety breaches, not to mention the loss of customers who come to think of you as unreliable.

As such, it is vital to put in place practises that ensure the systematic checking of your equipment, so you can catch issues ahead of time and make the necessary repairs. This is where an equipment maintenance plan comes in – and this is something you can schedule in on a more routine basis.

How often to check your machinery

When establishing an equipment maintenance plan, you should schedule in regular, thorough reviews of your entire production line and all the machinery within it. This should include checking whether everything is in good working order and inspecting the wear and tear to each machine.

As part of your plan, you should create a routine that details how frequently you will check your production line. Again, this may vary depending on the size of your plant, the machines you have and how often each system is used, as well as who is carrying out the maintenance on your behalf. A general rule of thumb could be monthly maintenance, though this may increase in the event of heavy use. It is essential to find a pattern that works best for you and the unique requirements of your production.

Each time you carry out scheduled maintenance, you should make a note of the status of each system. This will help you to keep track on wear and keep an eye on any machines you think may soon require repair or replacement of parts.

Alongside your maintenance plan, it is fundamental to create a culture where staff are encouraged to raise any issues with you as soon as they are spotted. As your employees tend to be the ones working with your machines every day, they are often the first to notice potential errors.

Indicators that your equipment could be due a replacement part include inaccuracies in output, inconsistent behaviour or other faults that affect the quality of your products (such as damaged goods, contamination or incorrect portions). Create processes so that staff can easily report such issues – even if on a minor scale – and seek to find the cause of the problem. This will help you to rectify problems quickly before they spiral out of control.

By implementing a regular maintenance schedule, you will be able to get ahead of any broken parts in your production line, which will allow you to proactively make replacements and optimise your results.

Building a stock of spare parts

While a maintenance plan will enable you to identify damage and replace parts before any severe issues arise, it is not advised to wait until you need the spare part to order it. This is particularly significant as most break downs will happen unexpectedly.

Depending on the source, parts can take several days to arrive at your plant. During this time, a slightly worn part could turn into a full-blown break in your machine – leaving you facing extended downtime and reduced productivity.

It is therefore worth building up an inventory of spare parts so that they are there when you need them. This means you will be able to carry out the repairs in good time so that you can reduce the effects on your production.

Order spare parts for the machines you have in your plant and aim to have at least one part available at all times. This will help you to build up a healthy stock, ready to be utilised when you need it, no matter what goes wrong across your equipment.

The benefits of maintained equipment

Having well-maintained equipment, with parts replaced when they need to be, can bring many advantages to your production line. As well as allowing things to run smoothly and preventing pauses to your operations, it can enable you to control the quality of your goods, stick to procedures, minimise contamination, reduce waste through incorrect products and maintain appropriate health and safety for your staff.

As a result of this, you will achieve a higher return on investment across your machines – benefiting your stakeholders and your customers.

If you need guidance in maintaining your machine or accessing spare parts for your equipment, Yamato can help.

We offer a range of spare parts, including bucket repair kits and checkweigher belts, at a competitive price. Our parts are completely genuine, ensuring compatibility with your systems and allowing for a long-lasting repair. They are also easy to install, following the instructions provided by us so that you can carry out the fixes swiftly in-house. A 12-month guarantee backs each part we sell for additional peace of mind.

Beyond this, we can also assist in the routine maintenance of your equipment through our service and repair contracts, supporting you in the upkeep of a well-serviced production line.