After upgrading from conventional to CNC milling machines, a South African replacement parts manufacturer expected greater efficiency and output. But just over a year later, costly downtime revealed an overlooked truth: state-of-the-art technology alone doesn’t replace sound maintenance.
Transitions to something deemed ‘better and bigger’ in heavy industries are usually a sufficient cause for celebration. This was no exception, about four years ago, at one component manufacturer in Johannesburg, South Africa. The company, a mid-sized outfit, was switching from conventional to vertical machining centres (CNC milling equipment).
The timing was perfect – there were more orders from clients, which, potentially, meant more revenue. Thus, to cope with demand and meet tight delivery deadlines, there was a need for more capacity in production lines. Moreover, ensuring machinery reliability was paramount.
In his speech, the company’s managing director, elated, declared that the challenges on the side of production were over. He highlighted: “The new state-of-the-art guarantees increased production, better precision, improved quality output, and lower costs.”
In response, staff on the factory floor ululated – a traditional South African vocal celebration – ushering in an era of modernisation.
The expectation – or perhaps the wish – was that this machine would offer consistent reliability without interruptions.
But the reality was different.
Eighteen months later, unplanned shutdowns occurred due to machine failure. In accordance with the warranty, the local supplier sent technical personnel to address the issue, which took two weeks to resolve.
Ironically, the ‘outdated’ conventional machines, which had been all but discarded, proved invaluable during this period – coming to the rescue and churning out components. There was something of a biblical moral twist to it: “The machines the factory rejected became its saviour.”
Cruelly, this experience revealed a critical oversight in the company’s approach to coping with new technology.
However, the acquisition had created unrealistic expectations about seamless and continuous production. Most likely, management looked at the finished perfect products and overlooked sound maintenance – the most cardinal of all. Key maintenance fundamentals, such as scheduled servicing, operator training, and maintaining spare parts for essential systems, had been taken for granted.
In the end, this was a lesson at colossal cost: Maintenance 101. What management overlooked was that, unlike in science fiction, where machines work without upkeep, in factory production lines, regular servicing, operator training, and contingency plans for unexpected failures are paramount.
Experts from KNUTH Machine Tools SA will share their insights on vertical machining centres with manufacturers in an upcoming feature article.
