LEARNING OBJECTIVE
- To provide comprehensive knowledge on preventive and predictive maintenance practices
- To understand the components and working principles of injection moulding machines
- To introduce the basics of hydraulic, pneumatic, and electrical systems in moulding machines
- To develop the ability to perform condition-based maintenance
- To enhance machine uptime, reduce breakdowns and extend equipment lifespan
WHO SHOULD ATTEND
- Maintenance Technicians
- Production and Process Engineers
- Maintenance Planners and Supervisors
- Technical Trainers and Facility Engineers
TRAINING METHODOLOGY
- Maintenance checklist templates
- Basic hydraulic, pneumatic, and electrical diagrams
- Condition monitoring samples
- Troubleshooting flowcharts
- Certificate of completion
COURSE OUTLINE
DAY 1: Machine Fundamentals and Preventive Maintenance
Morning Session:
1.0 Introduction to Maintenance Management
- Definition and importance of preventive & predictive maintenance (PM & PdM)
- Reactive vs preventive vs predictive
- Benefits: reliability, safety, cost saving
2.0 Types of Moulding Machines
- Hydraulic, electric, and hybrid machines
- Structure overview: clamping unit, injection unit, control system
- Basic machine operation and process flow
3.0 Key Machine Components and Their Functions
- Injection unit: screw, barrel, nozzle
- Clamping unit: tie bars, platens, toggle or hydraulic mechanism
- Hydraulic system: pump, valves, oil circuit
- Pneumatic system: air valves, cylinders, regulators
- Electrical system: sensors, PLC, HMI, relays, contactors
Afternoon Session:
4.0 Introduction to Basic Systems
- Basic Hydraulics: components, pressure control, fluid properties, schematics
- Basic Pneumatics: air flow control, valves, actuators, FRL units
- Basic Electrical: power distribution, fuses, overloads, grounding, wiring diagrams
5.0 Preventive Maintenance (PM) Planning
- PM scheduling (daily, weekly, monthly, yearly)
- Lubrication plan
- Filter, hose, and seal inspections
- Checklists and documentation
6.0 Practical PM Checks (Workshop or Video Demo)
- Oil level and quality check
- Heater band and thermocouple testing
- Cleanliness and ventilation inspection
- Hydraulic leak detection and electrical connection tightening
DAY 2: Predictive Maintenance and Monitoring Techniques
Morning Session: 7.0 Introduction to Predictive Maintenance (PdM)
- PdM vs PM comparison
- Data-driven approach and sensors
- Early warning signs detection
8.0 Condition Monitoring Tools
- Vibration analysis
- Infrared thermography
- Ultrasonic testing
- Oil analysis and particle count
- Real-time monitoring sensors
Afternoon Session:
9.0 Analyzing Machine Behavior
- Monitoring cycle time and part rejection
- Motor performance and power usage
- Screw torque, back pressure trends
10.0 Integrating PdM with Industry 4.0
- Smart sensors and IoT integration
- Machine data logging
- Alarm-based diagnostics and dashboards
DAY 3: Troubleshooting, Safety and Continuous Improvement
Morning Session:
11.0 Root Cause Analysis in Moulding Machines
- Systematic troubleshooting (5 Why, Fishbone diagram)
- Common failure modes (hydraulic leaks, overheating, poor clamping)
- Case studies and failure investigation
12.0 Safety in Maintenance Activities
- Lockout-tagout (LOTO) procedures
- Electrical and hydraulic safety precautions
- Personal protective equipment (PPE) use
Afternoon Session: 13.0 Maintenance KPIs and Documentation
- MTBF, MTTR, OEE basics
- Record keeping and trend analysis
- Digital vs manual systems
14.0 Final Group Workshop
- Simulated machine condition diagnosis
- PM & PdM improvement plan presentation
- Feedback and Q&A session
