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Increase Yield by Minimizing Machine Downtime

Posted by Robert Rourke on Feb 7, 2017 8:00:00 AM

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Your business makes money when your equipment is running smoothly. What may not be as obvious is how much is at stake if there’s unplanned machine downtime. In one case, an automobile manufacturer calculated a $22,000 per minute cost due to equipment failure.

Machine downtime is expensive. Regularly scheduled maintenance by a precision roll grinding service is your best defense against roll flaws or failures.

Be Prepared for the Inevitable

Machine downtime is inevitable. The plastics industry often sees outside contamination that damages high-temperature calender rolls. Metal wrapping around millwork rolls takes its toll on backing rolls. Food industries often experience loose tolerances that cause production issues.

Production downtime also disrupts workflow and momentum. That’s just the beginning. Companies may see greater risk of accidents, rising insurance costs, and expenses related to rethreading the production process. 

Treat the Cause, Not the Symptoms

Sometimes, the problem gets “solved” at the wrong end of the process. For example, a paper company experienced unwanted streaks in their product. To fix them, they added an expensive steam box to the wet end of the line. When that didn’t work, they tried a heater at the dry end.

The streaks continued.

The root cause of the problem were defective rolls.

In another instance, a press worker added ink to cover defects in the final product. The extra cost cut into the company’s profits.

The real culprit?

Barring in the roll.

Be Proactive vs. Reactive

It’s tempting to choose a fast fix in order to restore production. However, quick fixes are often akin to a bandage on a chainsaw wound: It simply delays fixing the root cause of the issue. The result? More maintenance, substantial downtime, and of course, the risk of profit loss.

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Reduce the Effects of Machine Downtime

No manufacturing process will ever be completely without downtime. A proactive approach with scheduled maintenance lessens the risk and effects. Scheduled maintenance assures that the production meets or exceeds your manufacturing needs.

We’re here to help, by working with you to optimize roll performance based on your company’s needs. Here’s a look at Precision Roll Grinders’ basic maintenance procedures:

  • We remove bearings to check for journal roundness and eliminate chatter.
  • We make sure the journal is concentric to the roll face to eliminate vibration and barring.
  • We improve your tolerances, if your machines running more than 10 percent faster than original design speed.
  • We test your rolls for optimized performance.
  • We make sure your rolls work at or better than OEM specifications.

Talk to Precision Roll Grinders to learn how precision grinding increases the life of your rolls, reduces the risk of downtime and protects your profit margins.

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