Which Machine Is Good For Metal Wire Straightening?

Metal wire straightening is an engineering work required for machines and tools. There are many products for which straight metallic wires are needed but the wires in distorted shapes. How these pieces are straightened? Could you it with your hands? You need some tools like a hook on which you can fix one end of the metallic wire and then you can stretch the wire.

Opening locks in the wires

Distorting of shape could form locks that can be opened even with hammer. If you try hammering the locks with force, you can break the pieces. To open locks, you need a device that can pull the wire with such a force that the locks get opened. You need a machine to do the job and you can easily buy the machine from market. It is available at affordable price and you don’t need a trained worker to run the machine.

Buy a machine for metal wire straightening and set it inside the factory where you work. Start the machine and run it at its optimal speed to see its output. It should do a great job. Here you should determine the amount of work you want the machine to do and prepare the factory accordingly. Straightened wires should be kept at a safe place for transportation.

The distorted pieces can be fed into the machine from one end and the straightened pieces can be drawn out from the device from the other end. The process will keep going until all the pieces are straightened. Here you need taking care that the pieces are fed right into the mouth and also there should be no complication while feeding the pieces into the straightener.

A heavy duty metal wire straightening machine can easily straighten tons of distorted wires but there should be proper place to keep the straightened pieces. You can hire an operator and give him the responsibility of running the machine in a hassle free manner. The operator will take care of the machine and make sure that it works perfectly. Also he can maintain the machine in good health.

Plugs And Their Importance Inside The Industry

When talking about Plugs we often refer to the ones which can be seen inside the various electrical appliances and equipment inside our homes and the workplace. However, in this article we will be referring to plugs in a different context altogether. These small and tiny sized devices are used for various industrial and manufacturing purposes. We will have a look at these unique gadgets and work out what exactly it is that they do.

As such a common product, dip moulding technology is often employed to mass produce these components in the style and sizing required. Each Plug can have many different uses and therefore are considered extremely versatile, some uses include to seal holes as well as to blank them off. Common inside a number of industries each Plug can adhere to exact needs and requirements, being made flexible or out of a particular material.

Different Shapes & Sizes

The best thing about using Plugs over alternate components is that they can become a cost effective and reliable source for finishing and completing products during the manufacturing process. It is because of this that they are produced in a huge array of different shapes, sizes and materials depending on the needs of a specific project. Some of the most common materials used include Vinyl, Polyurethane, LDPE & HDPE just to name a few.

Consumer Uses For Plugs

Along-side their use inside the Industry/Manufacturing, these kind of Plugs can also be found inside consumer households for general day-to-day uses. These uses, however general they may be, are effective in the sense that they easily complete a simple task such as filling or blanking off a panel hole.

Uses Inside the Manufacturing Industry

Plugs have a number of uses inside the Manufacturing Industry hence their wide availability. Coming in a number of different variants they can be used for almost anything such as:

To protect threads
To blank off a panel/hole
To add a finish to an application
To seal off a pipe or pole

As you can see, the uses found inside the Manufacturing Industry are similar to many consumer uses aside from the fact that they may be bought in much smaller quantities.

Materials Used

It would be pertinent to mention here that different grades of materials can be used depending on what it is they are going to be used for. For example a certain grade of PVC may be used to provide an added level of flexibility and tenacity to promote an air-tight fitting, preventing moisture, grime and dirt build up on the inside.

The different grades of material can help to ensure that shredding, resistance, splitting and insulation aren’t a problem further down the line when it would be too late to return or exchange. Another key reason for different grades of materials is to bring a different colour. Colours are often a high priority inside many industries to differentiate and to provide a clean, ideal finish. Some of the most common colours Plugs are produced in include:


Different Types Of Plugs

There is a huge number of variations of these products, mainly being separated into two main categories; These being Plastic Plugs & Rubber Plugs.

Rubber Plugs are regularly used for uses such as sealing and filling a hole, this is because of the properties that rubber provides as well as the cheap nature of the material. Rubber Plugs come in a wide range of styles depending on the uses you have for them, often coming with more advanced properties than their plastic counter-parts.

Some common types of Rubber Plugs include:

Silicone & EPDM Tapered Plugs
Blanking Plugs

Plastic Plugs on the other hand are often used for protection uses where the application may need screwing in, for example to protect a thread. Plastic Plugs are often the more cost effective option and are often deemed as a disposable product depending on what you use them for.

Some common types of Plastic Plugs include:

Threaded Plugs
Barrel Plugs

As a whole it is clear to see how important the different types of Plugs are in terms of their uses across Industry, especially inside Manufacturing where they are used every day to finish, protect and blank off.

Vital Parts are a major UK supplier into Industry for End Caps, Plugs, Tube Fittings and a whole range of useful components.

We pride ourselves on sharing a wide knowledge with our customer base, publishing a host of guides, measurement tips and general posts to help people understand our components and their uses.

The Principles And Objectives Of Material Handling

Materials handling is the art and science of moving, packing, storing and protecting of substances in any form until they are brought to further use. Like any other work material handling also works on certain principles and objectives. These have been defined and described in details us under:

Planning Principle: It is imperative to have a definitive plan before executing any work. Hence, the planning principle involves the method and timeline of keeping or moving the material as per demand of the consumer.
Standardization principle: When handling large scale of material handling, maintaining a standard is very important. Customization of material as per need can lead to wastage of the material thus resulting in dead stock. This is why the equipment, software and controls should be standardized in a pattern to provide maximum benefit.
Work Principle: The main objective of using the work principle is to ensure usage of handling equipment for movement of large-scale products is to minimize the load of work on the manual labor without having to compromise on the quality of the material handling.
Ergonomic principle: Ergonomics is the science that seeks to adapt work or working conditions to suit the abilities of the worker. Therefore, the ergonomic principle works on the objective of understanding the limitations of the manual labor and to ensure that maximum work can be extracted without having to put them in jeopardy.
Space Utilization principle: Since one of the prospects of material handling is storing of goods, the space utilization principle is important aspect to be covered. The space is three-dimensional and is calculated in cubic space to adjust the material without breaking it. The placement of material should be effective and efficient so as to keep it intact and make space for other products as well.
Unit Load Principle: While moving and storing the goods it is imperative to know the unit load of the goods so as to ensure that it is appropriately sized and configured in a way which achieves the flow and stock objectives at each stage in the supply chain.
System Principle: The objective of the system principle in material handling entails the movement; storage, protection and packing of the material should all work in a synchronized manner to make sure that the workflow is not hindered.
Environmental Principle: All the machinery required for the accomplishing the task of material handling should be keeping in mind the environment of the storage space. For example energy consumption should be considered as an environmental factor when performing the routine tasks of material handling. Effective usage of energy ensures least wastage.

Progressive Die For Sheet Metal Cars

Dies are very common in the automotive field. These molds are necessary to build almost every piece of a car, including exterior and some components in the engine.

Die production
Tool and die makers create dies and put them and mount them into a press to put them in production.
For the creation of sheet metal, such as automobile parts, two pieces may be needed: one called the “punch,” which performs the bending, stretching, or banking operation; and the second one, called “die block,” clamps the workpiece and gives stretching bending, and banking operations as well.
The workpiece has to go through several stages with different tools and operations to get the final form. If it’s an automotive component, there usually is a shearing operation after the main forming is complete, and then there’s an additional rolling or crimping operations to assure that sharp edges are hidden and verify the rigidity of the panel.

Die processes
The production of sheet metal for automotive cars often has through various die processes. Dies will mold, bend, and stretch a sheet of metal in different ways, and some of the most common die tools are:
• Blanking: the blanking die creates the flat piece of material by cutting the shape in one operation. The finished part is the blank.
• Broaching: the process where tool makers remove excess material by using multiple cutting teeth, with each tooth cutting behind the other.
• Bulging: the process uses oil or water to expand the metal part, and then uses a rubber pad to move the wall of a workpiece.
• Coining: a coining die squeezes the blank within a confined area, and the surface of the blank die would reverse the image on the front. It’s used to create flat metals like medals and coins.

Progressive die
Progressive die stamping is a metal forming process widely used by several automotive, electronics, and appliances industries, and is the single most important process for creating sheet metal for vehicles.
The process consists of various individual workstations performing one or more operations on the metal piece. The steel strip is carried from station to station automatically and is cut at the final station.
Progressive die produces a large number of parts for low costs, and it also meets high standards of precision, accuracy, and durability.
Because of the complexity of the process, there are essential tools to ensure the quality of the product. For example, the pilots have to fix the strip into the proper positions and maintain control over it.

3D Printing: The Materials Used for 3D Printing

3D printing was developed back in the early 80s but it has seen much growth since the past 10 years. It has now become one of the biggest growth areas in the tech industry and is revolutionising manufacturing covering every industry possible. The 3D printing business is now multi-billion dollar industry and is likely to continue growing at an exponential rate.

3D printing is quite a simple process conceptually, the printers work by printing the chosen material in layers on top of each other, with each layer setting prior to the next pass of the printer.

3D printers have been used to print all sorts of materials from cheap and normal materials to things you would expect to read in a sci-fi book.

For the consumer market, plastics are used exclusively as the materials are cheap to buy, but more importantly, the technology required to print plastic is relatively simple and low cost.

Low-cost 3D printers using plastic tend to use Fused filament fabrication (FFF). This is basically a process where a cord of plastic is heated up to become pliable then fed through the machine layering the plastic. The machines generally use one of the following plastics

PLA (Polylactic Acid) – PLA is probably the easiest material to work with when you first start 3D printing. It is an environmentally friendly material that is very safe to use, as it is a biodegradable thermoplastic that has been derived from renewable resources such as corn starch and sugar canes. This is a similar plastic that is used in compostable bags which safely bio degrade compared to more traditional plastics used in Poly Bags.

ABS (Acrylonitrile butadiene styrene) – ABS is considered to be the second easiest material to work with when you start 3D printing. It’s very safe and strong and widely used for things like car bumpers, and Lego (the kid’s toy).

PVA (Polyvinyl Alcohol Plastic) – PVA plastic which is quite different to PVA Glue (please don’t try putting PVA Glue into your 3D Printer, it definitely won’t work). The popular MakerBot Replicator 2 printers use PVA plastic.

Plastics are used extensively on all levels from consumer to businesses prototyping new products. However, in the business market, there is a huge demand for metal 3D printing. Some printers can use powdered material that is then heated to create a solid. This method is typically Direct Metal Laser Sintering (DMLS) and this particular technique is why we don’t see consumer metal 3D printing. DMLS requires a huge amount of heat and giant expensive printers to sinter the material together, and while 3D printing a metal object might be expensive compared to mass production, it is incredibly cost efficient for complex and expensive projects. A good example of DMLS based 3D printing is GE Aviation using it to produce 35,000 fuel injectors for its LEAP jet engine.

Using boring materials such as metal is almost archaic in the world of 3D printing now; some companies now do 3D bioprinting which is the process of creating cell patterns in a confined space using 3D printing technologies, where cell function and viability are preserved within the printed construct. These 3D bioprinters have the capacity to print skin tissue, heart tissue, and blood vessels among other basic tissues that could be suitable for surgical therapy and transplantation.

5 Energy-Saving Tips For Manufacturers

Are you worried about the current oil prices? If so, you should stop worrying as the price won’t last forever. Actually, OPEC has almost no influence on electricity or natural gas. The fact of the matter is that the old coal-based power plants increased electricity prices in 2016. However, the problem is that energy efficiency is really important for you should you want to stay ahead of the competition. If you are a plant manager and you want to save energy, we suggest that you follow the tips given below.

Process Heating

The US Department of Energy suggests that plant managers can cut down on the heating costs through the implementation of some energy-saving measures. As a matter of fact, process heating includes 30% of the energy consumed in this sector. Therefore, if you save energy in this area, you can make a significant impact.

Moreover, you can monitor and control your air-to-fuel ratio and exhaust gases in order to save a lot of energy. But if your plant requires lots of hot water, it’s a good idea to use a solar-water heating plant to preheat the process water. This is another great way of saving a lot of money.

Motors and Equipment

Machine drives accounts for over 22% of power consumption in the manufacturing sector. If you want to cut down on your operating costs, we suggest that you analyze the system and shaft losses. In addition, you can also consider upgrading to a system that is more efficient.

At times, you may have to replace the equipment to achieve your targets. But you don’t have to spend a huge sum for each upgrade. As a matter of fact, you can hone the mechanical performance of the plant through the alteration of the operational or maintenance procedures.


Typically, building-performance experts consider lighting as the main source of energy consumption. For energy saving, you can opt for fluorescent bulbs, fixtures, LED tube lights, and skylights, just to name a few. However, you don’t have to replace all of your lighting systems in order to save energy.


You may not want to overlook utilities as far as saving energy is concerned. What you need to do is review your usage plans and then get in touch with the service provider to find out if they can provide alternative procurement or other option that can help you save money.

Actually, some utilities offer attractive incentives for the installation of energy-saving improvements. It’s also a good idea to contact the competitors. You can also negotiate with them to get the best deal.


For energy efficiency, employee behavior also matters. You may want to let your employees know your goals and progress. Don’t forget to appreciate them for playing a role in the achievement of your goals. You will see that they have great insights. As a matter of fact, studies show that upgrades for energy efficiency help workers become more productive.

Why Installing An Industrial Transformer Is A Smart Choice

The transformer is the device that is designed with the aim to transfer constant power supply. They consist of two or more circuits that create the electromagnetic power between them. It is the best device which is known to provide the accurate power supply. Transformers are mostly used in the manufacturing sectors and each transformer serves different requirements. There are different types of transformers available in the market according to different industrial use. All the transformers have different capacities to handle the voltage supply, depends upon the equipment they are attached to. It is very important to choose the right kind of device to get the effective results. Many manufacturers offer a device chart that indicates the types of transformers and their voltage supplying capacity. It makes it easier for a customer to choose it carefully. Always buy from good manufacturers that are well-known for its quality products. Here are some of the benefits of installing a transformer.

Cost Efficient Device – Transformers are known as an essential device that can help to protect your appliances for high voltage. To save your costly machinery and appliances, the transformer can be a cost saving investment. This device is highly affordable and will not going to create the burden on your wallet. Investing in transformers can be a worth full choice.
Superior Protection Quality – A Transformer is the best device that helps to provide the best protection to your appliance by minimizing the voltage level. They are helpful to modify the current voltage. This device is usually made with superior technology that provides you the best results. It is also used to avoid the high voltage or short-circuit hazards.
Great Functionality – They are well-known to provide the constant power supply. Transformers are the best device that is the main component of a powerhouse. It is available in different variants hence, you can choose according to your industrial needs. Every transformer serves different requirement so, it is important to ensure your need before buying them. A transformer is a safe investment and a great device to use.

These are some of the benefits of having a transformer. It is easy to install and does not require a huge labor, hence it helps to save the installation cost. You can use it at your workplace to avoid short circuits. It is the best device that is highly affordable hence; you can buy it at a very low-cost. It is best suited for industrial purpose and known as the essential device for the electrical powerhouse. Try these transformers and offer a protection to your appliances.

The Advancement of the Valve Automation Industry

An increasing dependence on the use of digital valve positioners has made numerous changes in the valve automation industry over the past decades of being relatively unchanged.

With the advancement of our technology these days that made the whole world shift enormously to digital platforms, the industry has no excuse to not pay attention to those changes that may surely affect the industry big time. As a result, many plants now have the opportunity to take full advantage of the benefits offered by digital valve automation.

One of the major changes that the technology has influenced in the valve automation industry is the boom of its wireless capabilities. Because of the wireless technology there are a number of plants replacing more traditional methods of wireless valve control. Monitoring applications have been created for enhanced reliability, safety, environmental compliance, maintenance, and even personnel efficiency.

For this, there are two basic types needed for control: open loop and closed loop. In both cases, it becomes possible to reduce the alignment time, minimize worker exposure to chemicals and ladders that pose risks, and prevent human error that can result in lost batches or environmental spills. With wireless valve automation, making valves automated during the project planning phase is much easier.

Valve automation is broken down into a number of categories, each with unique services. These include electric actuators, fluid power actuators, manual actuators, limit switches, positioners, network capabilities, and more. Based on the type of industry and work involved, the appropriate application is used.

Key Benefits

Among the most immediate benefits that customers are able to glean from digital valve automation is the capability for auto-calibration. Additionally, customers have the ability to capture data in a much easier manner by utilizing a microprocessor. Basic data captures includes ambient temperature, valve odometer, operating pressures, and the histogram. While this kind of data was previously available with analog products, transitioning to digital technology has made it possible to benefit from greater positioning feedback.

Numerous options are also provided to the operator interface. Bus systems and local keypads are perfect examples. With all of these options, the operator has the ability to make quick, accurate, and efficient changes to a variety of different parameters such as close time, open time, flow characteristics, and dead band.

Despite the fact that bus system technology is actually more advanced, many customers find that HART technology offers a greater number of benefits. They have a more robust and simple design, as well as device portability that proves to be extremely convenient for a number of industries.

Implementing a New Strategy

If you are giving serious thought to implementing a new valve automation strategy in your facility, it is important to perform a comparison and assess various factors to choose the right type of valve automation for your needs. With this, you will be able to determine what will and will not work within your specific environment. In addition to considering the capabilities needed in the short-term you also want to think about future needs.

3 Keys to a Successful Preventive Maintenance Program

Preventive maintenance planning and practices influence most major maintenance department activities in a manufacturing environment. Here are some examples of this.

Equipment downtime is largely affected by preventive maintenance or the lack there of.
Repair work orders are subjected to the influences of the preventive maintenance program.
Purchasing and inventory are affected by preventive maintenance for routine replacement of expendable spares as well as repair parts required for unexpected downtime.

As evidenced by the points above, preventive maintenance should be “first base” for any maintenance department. Unfortunately sometimes routine preventive maintenance activities often do not get the attention or credit they are due. This is a mistake. So what are the keys to a successful preventive maintenance program?

1. Careful Planning of the Preventive Maintenance Program

Planning a preventive maintenance program involves the following:

Determine tasks and intervals needed to maintain the equipment.
Ensure that the appropriate resources are in place.
Schedule maintenance personnel for maximum preventive maintenance wrench time.
Understand how scheduled equipment downtime and maintenance personnel scheduling interface.
Manage spares effectively.
Select a scheduling and accountability system (preventive maintenance software, CMMS software or equivalent)

Determine Maintenance Tasks and Intervals

A good preventive maintenance (PM) task list contains the following components:

The equipment item.
The task(s).
The person the task is assigned to.
A task interval.
A start date and due date.
Optional: Detailed instructions and pictures if needed.
Optional: Task completion sequence.

Begin with your equipment list. Next gather appropriate tasks for preventive maintenance task lists from OEM manuals or online manuals when possible. This is a good place to start, especially with newer equipment. In some cases, the equipment warranty is dependent upon following the OEM recommendations. Another source of tasks is the maintenance manager’s experience and intuition. Yet another source is branch locations running similar equipment.

When developing a task list, consider the reusability of the task descriptions. Reusability refers to using the same task description on potentially multiple equipment items. The benefit is that there are fewer tasks, no duplicate task descriptions and better reporting and analysis of PMs. Consider these examples:

REUSABLE task description: Lubricate Roller Chain(s)

NOT REUSABLE: Lubricate Roller Chain(s) on Conveyor #1

In the first example this task, Lubricate Roller Chain(s), is appropriate for any equipment with a roller chain. In the second example, Lubricate Roller Chain on Conveyor #1, is only appropriate on the Conveyor #1 PM task list. Imagine how cumbersome your preventive maintenance software management efforts become if you are not using reusable tasks. Another example that may cause problems later is naming conventions such as 30 Day PMs or Weekly Tasks. This creates unneeded redundancy, as the interval (30 in this case) is included in the PM record already. Additionally there is no task description here that refers to the actual work performed.

How do you create reusable tasks? Begin with the most generic tasks you can think of and create these first. Examples could be Inspect, Clean, Lubricate, etc. After these task descriptions have been created, go to the next step and create tasks that are somewhat more specific. Here are some examples: Check Wiring, Replace Lubricant, Lube Chains. Continue with increasingly more specific tasks always trying to avoid including the equipment or equipment component in the task description. Eventually, for specialized tasks that are only performed on specific equipment, it may become necessary to include a component of the equipment in the task description. Keep the task description short and focused on the actual task. Obviously if the task description is short, it may not fully describe the job. This is where detailed instructions and pictures are used.

Next, determine what interval units are needed for your PM system. Calendar-based PMs usually will use a day interval. For example every 7 days Lubricate Roller Chain(s). Other tasks may be demand based or based upon the actual runtime of the equipment. In some cases, hours or minutes may be appropriate. As you gain experience with this set of PM tasks and intervals changes to the tasks and intervals may be warranted. Consequently choose a system that makes editing existing PMs simple and without historical data loss.

Ensure that Adequate Resources are in Place

Listed below are resources you need for a successful preventive maintenance program:

Trained and available personnel.
Adequate spares, expendables, lubricants, drive chain, bearings, etc.
Time in the production or equipment runtime schedule to perform PMs.
A motivated team of maintenance professionals.

Personnel must be trained and capable of safely performing the required work. Vigorously enforce proper lockout/tagout procedures. Stock on hand for expendables and other spares used for PMs has to be adequate. Inadequate spares not only prevents completion of the PMs, but also hurts motivation when personnel attempting to perform their job are hindered by a lack of spares. As such, the purchasing department has to have an ordering system that stays ahead of preventive maintenance spares requirements. Additionally an accountability system (CMMS) helps track spares use for restocking purposes. In summary, show your maintenance technicians how important you believe preventive maintenance is by providing the materials and training needed for these important tasks.

Time is a resource. Time must be available so that personnel can perform their work. This may require scheduling changes so that maintenance personnel are available during scheduled equipment downtime. Given the right resources, your maintenance team cannot help but be motivated to succeed with equipment maintenance.

Use a Maintenance Software Solution to Track and Manage Maintenance

Now that the tasks, intervals, personnel, training and scheduling are established it is time to load the data into a preventive maintenance software system. With so many CMMS choices, it is important to do your research carefully. Approximately fifty CMMS companies go out of business annually and fifty more replace these. Choose a well-established long-term CMMS company that has a proven record of accomplishment. Ask the following questions when choosing a CMMS:

How long has the CMMS company been in business?
How flexible is the preventive maintenance system?
Are there different task list formats available?
Is it possible to automate task list issuance?
Do technicians have the ability to close their own PMs while maintaining the integrity of the data?
Is it possible to close PMs without leaving the plant floor?
How easy (or hard) is it to adjust preventive maintenance task schedules?
Are labor and parts costs easily summarized and reported?
Is there an objective way to know how to optimize task lists or task intervals based upon downtime or reliability data?

When evaluating a CMMS it is best to run a demonstration copy of the proposed system with your own sample equipment and tasks. Use the system for at least 30 days. Issue preventive maintenance task lists to your personnel. Get their buy-in by demonstrating the usefulness of the system. Prove to yourself and your maintenance technicians that using the software makes both of your jobs easier. Most importantly confirm that this system has the potential to improve equipment availability and reliability.

Consider support and training as part of the initial investment. CMMS software training is well worth the investment as it brings the maintenance department up to speed quickly with the CMMS and instills confidence in its use. This leads to better compliance in entering and updating data.

Price is important, however the real cost benefit of CMMS comes not from the initial investment in CMMS but in the ongoing use and benefits derived from that use. Some CMMS software solutions are subscription-based. Others are a one-time investment with a perpetual license. While there are several factors to consider in CMMS selection, initial investment (price) should be a low priority when the budget allows. Ask yourself this question: “Do you want to trust millions of dollars in equipment assets to a cheap CMMS?”

2. Implement Your New Preventive Maintenance Program

Now it is time to start reaping the benefits of your new preventive maintenance program. Here are a few questions to consider when implementing your new PM program:

Should tasks lists be printed, emailed or simply viewed through a tablet or smart-phone?
How are tasks closed and what data should be included?
Who should close the preventive maintenance tasks as they are completed?
What will you use the system when maintenance personnel are absent?
Should spare parts lists be included on the task list?
If spares are included on the task list, should stock levels automatically draw down when the PM is completed?

The answers to these question come down to company policy, industry requirements, regulations and personal preference.

3. Assess and Adjust Your Equipment Maintenance Program

Constantly assessing your preventive maintenance program is an integral part of managing this system effectively. Equipment runtime schedules change, equipment demand changes, personnel change, maintenance technologies and procedures change. Your primary assessment tool is equipment maintenance data. The longer you use your CMMS system the more data it accumulates. Assuming that you chose a CMMS that provides extensive analysis and reporting, this data is now a valuable decision-making store. Use this data for OEE (overall equipment effectiveness) and reliability analysis. Choose a CMMS that uses MTBF (mean time between failures) to suggest preventive maintenance task intervals. Using real runtime data to set PM task intervals eliminates guesswork.

Being a proactive maintenance manager you should be adjusting to these changes as needed. Here are some things to look out for and some ideas on how to react. Keep in mind that sometimes there is no substitute for an experienced maintenance manager’s intuition.

Equipment Runtime Schedule Changes

In some situations, preventive maintenance can only be performed while equipment is in a scheduled shut down period. This creates a problem for maintenance scheduling. Here are some ways to manage this situation.

Non-maintenance machine operators can complete some simple maintenance procedures such as minor lubrication tasks.
Double-team certain equipment when it is down.
Adjust maintenance schedules.
Use automated maintenance devices, such as lubricators.
Implement preventive maintenance procedures during unscheduled downtime.

Equipment Demand Changes

Equipment demand relates to more than just runtime schedule changes. Demand reflects the actual time equipment is running and how much work it performs during the scheduled period. Obviously triggering PMs based upon calendar days would not be appropriate in these cases. It is best to trigger PMs in this case based upon runtime hours, cycles, cuts or whatever the appropriate meter unit is for that equipment. Consequently this equipment should have a counting device or be connected to the system that automatically triggers preventive maintenance work orders through an OPC compliant data connection.

Select a CMMS software solution that reads OPC data directly from the equipment then automatically responds with a preventive maintenance work order at exactly the right moment.

Personnel Changes

The best way to overcome this inevitable change is to have detailed listings of preventive maintenance tasks, intervals, spares requirements and history. Make sure this information is available to pass on to the new person. The more organized your system is the easier is to move seamlessly through this change. Once again, a good preventive maintenance software solution addresses this need.

Additionally, ongoing training and cross training in various maintenance processes can offset personnel change issues.

Changes in Maintenance Technologies and Procedures

An example of this type of change could be a new sensor that provides critical maintenance data to an OPC server. This data in turn indicates the correct PM interval. Another example could simply be running the equipment only when needed. This action saves energy resources and may reduce wear and tear on the equipment.

Software is constantly improving. Desired options with preventive maintenance software solutions are as follows:

Is there a role-based permission capability that allows the maintenance technicians to close their own PMs?
Is there a mechanism to validate PMs closed by technicians?
Does the ability to temporarily assign tasks to an alternate maintenance technician exist?
Is it possible to gather runtime data through an OPC compliant data network and issue work orders automatically.


Preventive maintenance is the one of the primary responsibilities of the maintenance manager in a manufacturing environment. Many maintenance department activities are affected by, and rely on a successful preventive maintenance program. More importantly, success of the manufacturing facility as a whole is directly proportional to the quality of the design, implementation and management of the preventive maintenance system.

Top Tips to Choose the Best Connectors

From smart phones to sophisticated machineries that manufacture them, you can find an electrical connector in many forms. If you are an electrical industrialist or purchase engineer, it is essential to have some key factors in mind before making your final choice.

Here are a few essential aspects to check while choosing a connector:


Power of the connector is a determining factor. The market offers a wide range of connectors with different power-ratings. Identify your requirement and choose the one that meets the purpose.

A low power variant may not give you the expected efficiency and on the other hand, a high power connector can even damage the entire system.


The density of a connector is yet another influential factor in the present day. The higher the connector density, the more compact your machine design will be. This is especially important in case of complex machineries. In order to keep it solid at the same time give exceptional performances, it is essential to choose a high-density connector.

Temperature Resistance

Another important feature that adds to the quality of a connector is its capacity to withstand high temperatures. Most of these connectors are used in intricate machineries and they undergo immense heat exposure during their functioning. High-end connectors are often passed through multiple levels of testing to ensure its temperature resistance.