Maintenancepm

What this skill does

# 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"

---

## 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 |

---

## DMG MORI Machines

### Daily Checks (Operator - Every Shift)

```markdown
# 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)

```markdown
# 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)

```markdown
# 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

```markdown
# 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 | | | |

---

## HARDINGE Precision Lathe

### Daily - Operator

```markdown
# 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

```markdown
# 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 | ☐ | |
```

---

## CITIZEN Swiss Machines

### Daily - Operator

```markdown
# 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

```markdown
# 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 | ☐ | |

---

## MITSUBISHI EDM

### Daily - Wire EDM

```markdown
# 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

```markdown
# 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 | ☐ | ☐ |
```