The Problems of Time- and Usage-based Preventive Mold Maintenance
Updated: Jun 19, 2020
Preventive Maintenance (PM) is Inefficient
For all the talk about doing maintenance before failure occurs, the reality is that preventive maintenance is time-consuming and inefficient.
What we see most commonly in factories today are two types of preventive maintenance (PM):
Time-based PM scheduling maintenance after a mold has been active for a set amount of time.
Usage-based PM scheduling maintenance after a mold has completed a set number of “shots”.
Either way, the "problem" is that PM tries to prevent mold failure by estimating a schedule for when molds might need maintenance.
The Side-Effects of PM
PM means that a mold could go through maintenance when they don’t need it; it could be over-maintained.
Conversely, the mold could also not get maintenance when they actually need it; the mold will be under-maintained:
These side-effects mean that PM can be inefficient and costly.
To truly be efficient, engineers and managers need to schedule maintenance not by time- or usage-based estimation, but based on rules concerning the actual condition of the molds.
Move Beyond Preventive Maintenance
To move beyond PM, tooling managers should use sensors to monitor the data/conditions of molds in real-time. If these conditions reach a certain predefined threshold, tooling managers can be alerted, and maintenance can be conducted exactly when molds need it, thus saving labor and repair costs and minimizing downtime.
This is “rule-based predictive maintenance”. It is far more efficient than PM and only possible through real-time data tracking and dedicated analytics.
Predictive maintenance is the ideal; but for now, it may be enough to augment your current maintenance practices with real-time data tracking.
This is part of how eMoldino provides value to OEMs. Contact us to discuss how we plan on augmenting maintenance for our clients.