MaintenancePM - Preventive Maintenance System
Purpose: Protect capital equipment investment through systematic preventive maintenance.
When to Activate
- "What's the PM schedule for NLX2500?"
- "Create maintenance checklist"
- "What's due for service?"
- "TPM checklist for Swiss machines"
- "Maintenance history for [machine]"
- "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 | ☐ | ☐ | Reading: ___μS |
| 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 |
MTBF Calculation & Data-Driven PM Intervals
How to Calculate MTBF
MTBF (Mean Time Between Failures) = Total Operating Hours ÷ Number of Failures
Example: Machine runs 2,000 hours and has 4 breakdowns → MTBF = 500 hours
Setting PM Intervals from MTBF
| MTBF Result | Recommended PM Interval | Rationale |
|---|
| MTBF = 500 hrs | PM at 350 hrs (70% of MTBF) | Intervene before predicted failure |
| MTBF = 200 hrs | PM at 140 hrs (70% of MTBF) | High-failure item needs more frequent checks |
| MTBF = 1000 hrs | PM at 700 hrs (70% of MTBF) | Reliable item, less frequent PM justified |
Rule: Set PM interval = 70% × MTBF to catch deterioration before failure occurs.
MTBF Tracking Template
# 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
- PlantCapability: Factor maintenance windows into capacity
- SkillsMatrix: Who is trained for which PM tasks
- TribalKnowledge: Capture maintenance tips and tricks
- OEETracker: Availability component of OEE
