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 |

---

Downtime Tracking

# 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