Maintenancepm | Skills Pool
Maintenancepm Preventive maintenance schedules for MNMUK machine shop equipment. Covers DMG MORI, CITIZEN, MITSUBISHI EDM, Haas, and support equipment. USE WHEN user asks 'PM schedule', 'maintenance', 'service due', 'machine maintenance', 'what maintenance', or 'TPM checklist'.
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
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更新时间 2026年3月29日
职业 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) # 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
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 | ☐ | |
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 ☐
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 ☐
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 ☐
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
Maintenance Log Template # Maintenance Log
Machine: _____________
Machine ID: ___________
| Date | Type | Hours | Description | Parts Used | Tech | Time |
|------|------|-------|-------------|------------|------|------|
| | PM | | | | | |
| | Repair | | | | | |
| | PM | | | | | |
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
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
Integration
PlantCapability: Factor maintenance windows into capacitySkillsMatrix: Who is trained for which PM tasksTribalKnowledge: Capture maintenance tips and tricksOEETracker: Availability component of OEE 02
When to Activate