August 2026 Volume 8

MAINTENANCE

HOW TO MINIMIZE DOWNTIME DURING UPGRADES OR RETROFITS By Jeff Fredline

A ll mechanical systems and machinery require periodic maintenance, upgrades and retrofits. Often, the process causes unplanned downtime because of planning issues or unforeseen damage that expands the scope of work. This article will address a method of proceeding with the project that can greatly reduce delays and downtime. Project Pre-Planning Audit We begin by mapping the entire scope of the project. We track machine data, including runtime, downtime, uptime and idle time. Benchmarking will help us to understand the condition of the machine in question. We then begin the evaluation process by asking the following questions: • What are the objectives? • Are the objectives obtainable? The next step is determining exactly where the machine is now. A complete machine inspection to understand its overall condition and proper function is the first critical step. Let’s consider a forging press. All components of the press must be in good condition for the machine to consistently provide the desired outcome from each period of operation. (See Table 1) • What pieces of equipment will need to be upgraded? • What pieces of equipment will need to be replaced?

and rebuilding process leading to the upgrading of the equipment. First begin by listing the various machines and components of the work cell that require upgrades. Bushing Clearances, Wear and Leaking Seals Based on our inspection results we determine the working scope to most effectively obtain the desired outcome. An example would be following the lift clearance checks on the crankshaft and main bushings. If the clearance or level of wear is acceptable and does not require replacement, we can remove it from the list of items requiring repairs or replacement. If the clearance between the upper connection and the crankshaft shows excessive wear, we then add it to the list of repair items. At this point we begin the process of preparing for replacement. If you have prints for the connection bushing, you can reach out to suppliers for replacement costs and deliveries. As long as you have prints with accurate dimensions for the crankshaft and OD, ID and length of the bushing, you can order the material with stock for finish machining ahead of time and have it in stock so that as soon as you verify the finish dimensions you can begin the final machining process which will minimize your downtime. Note any leaking seals and plan for their replacement. Gear Train Most of the gears have guarding systems that have inspection covers or ports. One prime indicator of gear wear issues is excessive gear noise. With the covers open on the gearing guards rotate the gears, and visually inspect to get a clearer view of the actual condition of the gearing. If your visual inspection shows issues with the condition of the gears further inspection should be conducted. This inspection will require removal of the guards, cleaning of the bull gear and pinion teeth and deburring of any worn areas. Also verify alignment of the pinion to bull gear relationship. Gearing allowed to run off center will result in pre-mature failure. Upon completion of your inspection and cleanup of the gearing, measure and record the backlash and take pictures of any worn areas, which becomes a part of the PM records for the machine. Finally, apply lubricant and reinstall guarding. If there is severe wear that will require replacement of the gearing this will give you the opportunity to get the gears on order as the lead time will be extensive. Usually you can continue to run the machine while the gears are being manufactured. Motor Controls and Drive Start by examining the control panel. Test each of the push-button controls and switches. Note any that are not functional. Test the motor starter system to ensure proper function. Open all panels and visually check for condition of the wiring and components. Is the panel clean and free from loose wires and jumpers? If an electrical system upgrade is part of the plan, make sure to obtain all necessary information for replacement. If there are light curtains or other safety devices are the properly located and do they function properly? Does the point of operation guarding require repair or replacement?

TABLE 1

Ram assembly and wear surfaces

Critical Areas to Be Inspected: Condition of gear train

Condition of all bearings and seals Wedge arrangement for die space adjustment

Motor controls and drive

Knockouts

All bushing clearances

Many of these checks should be made as a part of normal maintenance and monitoring functions. Items that require replacement can be long lead time items and planning for their replacement ahead of time will prevent unplanned down time during the process. Once we have completed the first steps, we should be able to calculate the overall equipment effectiveness. OEE which is calculated by the follow formula: OEE=Availability x Performance x Quality Project Planning Now that we have obtained the best information we can to evaluate the various machine systems, we can move to the project planning stage. Based on the data obtained during the inspection process we can accurately begin to plan for the repair

24 FIA MAGAZINE | AUGUST 2026