Across several hundred service visits, a pattern emerges: the catastrophic failures are rare and usually unavoidable, while the minor faults that stop a line for two hours are almost always traceable to one of five habits.
1. Listen For The Labels
A labeler running with a slightly worn peel plate makes a sound operators learn to ignore. That sound is the machine telling you it is now placing labels a fraction off-centre. Swapping a peel plate costs a few euros; a mislabelled pallet costs a customer.
2. Keep A Spare Set Of Wear Parts On Site
The most common cause of a two-day stoppage in our records is not a failed part — it is a part that failed overnight and could not be obtained the next morning. A labelled drawer with the top twenty wear parts for your machine removes this entire category of downtime.
3. Filter Air, Not Just Water
Pneumatic equipment fails on dirty air long before it fails on worn parts. A filter change every six months costs almost nothing; a solenoid valve that fails mid-production does.
4. Record Torque, Not Just 'Tight Enough'
Torque values drift as capping heads wear. A line that records every closure torque has a trend; a line that does not has a surprise. Our capping machines export this data over OPC-UA for exactly this reason.
5. Train The Night Shift Properly
Most lines we visit have a well-trained day shift and an improvised night shift. Small adjustments — a slight speed increase, a shortcut on the guard — are made under time pressure and never documented. Train the night shift exactly like the day shift, and keep a shift handover log.
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