Maintenancepm

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"

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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

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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

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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 | ☐ | |

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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	☐

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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	☐

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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	☐

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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

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Maintenance Log Template

# Maintenance Log

Machine: _____________
Machine ID: ___________

| Date | Type | Hours | Description | Parts Used | Tech | Time |
|------|------|-------|-------------|------------|------|------|
| | PM | | | | | |
| | Repair | | | | | |
| | PM | | | | | |

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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

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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

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Workflow Routing

Trigger	Action
"PM schedule for [machine]"	Look up machine section, output relevant interval checklists
"What's due for service?"	Present Maintenance Schedule Summary tables
"Create maintenance checklist"	Generate daily/weekly/monthly checklist for named machine
"TPM checklist"	Output TPM level table + appropriate operator checklist
"Maintenance history"	Provide Maintenance Log Template
"Spare parts / what to stock"	Output Critical Spares table
"MTBF / PM intervals"	Explain MTBF calculation, provide tracking template

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Examples

Example 1 — PM schedule lookup

"What's the weekly PM for the NLX2500?" Responds with the Weekly PM - DMG MORI Turning Centre checklist including chuck pressure, turret indexing, bar feeder, coolant filter, and live tooling checks.

Example 2 — Upcoming service

"What maintenance is due this month for the CITIZEN Swiss?" Responds with the Monthly CITIZEN checklist: full oil tank clean, replace oil filter element, guide bushing check, Z-axis gibs, spindle accuracy, and cabinet cleaning.

Example 3 — TPM checklist generation

"Generate a daily TPM checklist for the Mitsubishi Wire EDM" Responds with the Daily PM - MITSUBISHI Wire EDM checklist covering dielectric level, conductivity, wire path, filter pressure, guides, flushing nozzles, wire tension, and auto-threader.

Example 4 — MTBF-based interval

"Our NMV3000 has had 4 breakdowns in 2000 hours. What PM interval should we use?" Calculates MTBF = 500 hours, recommends PM at 350 hours (70% × MTBF rule), and suggests updating the Monthly PM frequency accordingly.

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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