“We repair all units as long as they are still in a condition that allows them to be loaded with a fork lift onto a truck,” says Klaus Meyer, repair and preventive maintenance manager at the Lübbecke site. With his three-person team, he repairs everything – from combination and flush-milling units, through profile scrapers, drill spindles, tracer spindles, glue applicators and flat scrapers, to drill gearboxes and vacuum blocks – only to mention a few. The goal is to help customers in a fast and uncomplicated manner whenever units are defective.
The repair department, such as presented today, has only existed since 2010. Before that time, repair maintenance was carried out by the department that was responsible for the production of the unit. This was not always possible, however, because any such repair maintenance necessitated stoppage of production, and hence customers often had to wait a long time for the overhauled subassembly. Therefore IMA Schelling decided to set up its own department for this type of work.
Maintenance of contour milling units (KFA) is a recurring job of the maintenance team. "A KFA should be sent for repair approximately every five million cycles, i.e. after it has machined five million workpieces,” explains Meyer. In this process, the time needed for the repair of a complete KFA unit is usually 35 to 40 hours. It all starts with a damage analysis and a cost estimate. If the maintenance manager is given the OK to repair the unit at this cost, he and his team will carry out the repair and a final function test. As a consequence, his team has evolved into a group of KFA specialists that also consults customers how to use these units if required.
Whenever possible, repair maintenance on any of the subassemblies will be carried out at times when the plant is not operating. If this is not possible, the customer will get a replacement unit on request. Some customers have replacement units which are used in that case. Hence, plant shutdown due to repairs can be limited to max. one shift.
According to Meyer, a classification into two categories, i.e. operational or defective, would suffice for most subassemblies. But not for combination units and flush-milling units—here damages are subdivided into classes. IMA uses 4 different classes of damages depending on the type of problem and the scope of required spare parts and installation work (see table 1). „In the event of damage to a unit, these damage classes make cost estimation easier for our customers,” explains Klaus Meyer.
In addition to his repair maintenance jobs, he together with his team supports the other departments in constructing new units, tests purchased robot heads to make sure they are perfectly operational before they are installed, and if required consults customers how to use drill gearboxes and KFAs.
Moreover the repair maintenance team also carries out installation orders. This is the case specifically in summer and winter when customers use their annual closings for repairs and routine maintenance.
The team: Klaus Meyer, Janes Hussmann, Tomasz Rachwalski, Torben Gläscher