Production maintenance

Maintenance in production encompasses all measures taken to keep machines and equipment operational or to restore their functionality after a malfunction. This includes inspection, maintenance, repair, and improvement. Leadec supplements these core tasks with maintenance management, failure analysis, TPM, equipment optimization, spare parts management, regulatory inspections, and fieldbus technology. The goal of production maintenance is to ensure high equipment availability with predictable costs and as few unplanned downtimes as possible during ongoing manufacturing operations.

Machine maintenance involves scheduled tasks designed to delay wear and tear and maintain operational condition, such as lubrication, cleaning, adjustment, or the replacement of specific wear parts. Repair, on the other hand, is performed when a function is already impaired or has failed and must be restored. In professional industrial maintenance, both approaches work together. Leadec combines preventive maintenance with reactive repair and adjusts maintenance intervals to meet manufacturer specifications, technical standards, and operational data.

Preventive production maintenance is carried out on a scheduled basis before a failure occurs. Reactive maintenance begins after a malfunction or defect. A purely reactive approach may be cost-effective for non-critical components, but it increases the risk of unplanned downtime for production-critical machinery. Leadec combines preventive machine maintenance with rapid troubleshooting and on-call or shift services. The appropriate strategy should be determined for each piece of equipment based on criticality, the consequences of a failure, costs, and technical specifications.

A maintenance plan begins with complete equipment master data and an assessment of which machines are particularly critical for production, safety, or quality. Tasks and intervals are then determined based on manufacturer specifications, standards, and operational experience. Leadec can create maintenance instructions and integrate the planning into the customer’s ERP system or its own system. Malfunctions and documented defects should be evaluated regularly so that maintenance intervals are not static but are adjusted to the actual condition of the equipment and the production schedule.

A failure analysis does not merely examine the defective component; it also seeks to identify recurring causes and patterns. To this end, failure reports, the time of occurrence, operating conditions, repair measures, and—where applicable—measurement data are documented. Leadec uses this information to optimize maintenance schedules and equipment. The goal is not merely to repeatedly repair recurring faults, but to eliminate their technical or organizational causes. A structured database also improves spare parts planning, prioritization, and the evaluation of improvement measures.

Total Productive Maintenance (TPM) integrates production and maintenance more closely into plant maintenance. For example, simple, clearly defined tasks can be performed closer to the shop floor, while complex technical activities remain the responsibility of specialists. Leadec supports the implementation of TPM systems, employee training, and the planning of non-time-critical repairs. The goal is to achieve higher equipment availability through clear standards, early detection of deviations, and better coordination between operations, production, and industrial maintenance.

Digital systems provide transparency regarding maintenance schedules, malfunctions, tickets, equipment status, and completed tasks. Leadec uses, among other things, mobile documentation, ERP systems, Leadec.os, monitoring, and remote services. This allows defects to be recorded directly at the equipment and information to be analyzed centrally. The greatest benefit is realized when master data, maintenance schedules, and fault reports are consistently maintained. Digitalization does not replace technical maintenance, but it supports prioritization, documentation, and continuous improvement.

If a critical spare part is missing, even a quick fault diagnosis can lead to a lengthy production shutdown. That is why component identification, criticality assessment, inventory strategy, and inventory optimization are all part of industrial maintenance. Leadec assists with the selection, procurement, storage, inventory management, and obsolescence management of spare parts. The goal is not to keep as many parts in stock as possible, but to find the right balance between availability and tied-up capital. Maintenance and failure data help to tailor inventory levels more precisely.

Different inspection requirements and technical regulations apply depending on the machine, system, and equipment. Leadec provides support for legally required inspections of safety devices, machines, systems, and equipment, as well as for reviewing safety-related documentation. Any defects identified can be corrected immediately or reported to the operator along with recommendations for action. The specific inspections required must be determined for each location and type of system. Centralized management of deadlines and documentation reduces the risk of missed deadlines.

An external maintenance partner can be a good option when the goal is to relieve the burden on internal staff, supplement specialized knowledge, or professionalize the entire maintenance process. Leadec offers services ranging from inspections and machine maintenance to on-call service, spare parts management, and workshop organization. It is important to ensure a clear handover of equipment knowledge, documentation, and responsibilities. Service levels should be tailored to the criticality of production. This allows production maintenance to be outsourced without losing control or technical transparency.