Machine Maintenance Checklist

Confirm with the production supervisor that the machine is released from the schedule for the PM window. Note the work order number in the CMMS (Fiix, eMaint, Limble, MaintainX) before energy isolation begins.

Follow the machine-specific LOTO procedure posted at the disconnect (29 CFR 1910.147). Isolate electrical, pneumatic, and hydraulic energy. Each authorized worker applies their own personal lock — no shared locks, no exceptions.

Try-to-start the machine at the operator panel. Bleed residual hydraulic and pneumatic pressure at the test ports. Confirm stored energy in capacitors, accumulators, and gravity-loaded components is dissipated or blocked before any guard is opened.

Per the JSA: cut-resistant gloves for guarding work, chemical gloves and splash goggles for coolant or hydraulic oil, hearing protection if adjacent lines are running. Check the SDS for any solvents used in this PM.

Scan for cracked weldments, oil weeps at fittings, coolant under the bed, abraded cable jackets, and missing fasteners. Photograph anything questionable for the CMMS record — pictures resolve a lot of arguments at the next PM.

Inspect tension, alignment, glazing, and tooth wear. A belt that deflects more than 1/64" per inch of span is loose; replace V-belts in matched sets, never singly.

All fixed and interlocked guards present and torqued (29 CFR 1910.212). Test each E-stop and light curtain after re-energization at the end of the PM. A bypassed interlock is a citable finding and a top cause of amputation incidents.

Replace at the OEM interval or sooner if differential pressure is at limit. Log filter part numbers in the CMMS so the spare parts crib reorders against actual usage instead of guesswork.

Look for discoloration on lugs, loose terminal screws, and dust accumulation on contactors. Torque-check critical lugs to the panel schedule. NFPA 70E PPE applies if the cabinet is energized for any reason — this PM should be done de-energized.

Use the OEM-specified grease and quantity — over-greasing blows seals and is a top cause of premature bearing failure. Wipe zerks before applying the gun. Note any bearing rumble or excess heat from the last run for follow-up vibration analysis.

Compare gauge readings to the machine nameplate setpoints. Inspect hose ends and quick-disconnects for weeping. Sample hydraulic oil if it is at the ISO cleanliness sampling interval.

Any gauge or sensor used to verify a controlled spec must be in calibration per ISO 9001 / IATF 16949 7.1.5. Past-due gauges get red-tagged and pulled — no exceptions, even if the reading 'looks fine.'

Reference the parent PM work order. Capture the failed component, suspected root cause, and parts needed. Tag the WO with criticality so the planner can sequence it against production.

If the machine is safe to run with limits (reduced feed, specific part numbers only), document the restriction and notify the production supervisor and operators on the next shift. If unsafe, red-tag and remove from the schedule.

Each authorized worker removes only their own lock, in reverse order of application. Confirm tools and rags are out of the machine envelope before re-energizing.

Cycle the machine without product first, then run a test piece. Trigger each E-stop and interlock; confirm the machine stops as designed. Defective safety devices block release back to production.

Enter actual labor hours, parts consumed, meter reading, and any deferred work. The CMMS history feeds MTBF and PM compliance reporting — sloppy closeouts erode both.

Brief the operator on anything changed during the PM (new belt, recalibrated sensor, deferred work). Note it in the shift log so the next shift inherits the context.