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Prolific Engineering & Services (PES) has a long experience with the repairing of furnace failure and customer specific items for preventive maintenance. We have researched for the key experienced failure modes and find out solution to prevent the occurrence with  is Preventive Maintenance (PM) Package.

Types of Maintenance

It is also called breakdown maintenance, which is a maintenance task that is performed in order to rectify and repair problematic systems and equipment. The purpose of corrective maintenance is to restore broken-down systems.

Usually, it is performed by the maintenance department, but for some equipment or spare part that can’t be repaired by the maintenance department, PES Engineers are ready to support.

Please see the reference below:

It is a planned activity at regular intervals (time-based, periodic inspection, and overhaul) to eliminate causes of equipment failure and unscheduled interruptions to production, as an output of the manufacturing process design. [IATF, 2016]

According to the above requirement, the aim is to ensure maintaining the effectiveness of the production process. The concept is to check equipment and change key spare parts at the planned interval before equipment to be a breakdown.

In order to fully support customers, PES has launched a Preventive Maintenance (PM) Package for customers, see the information below:

An approach and set of techniques to evaluate the condition of in-service equipment by performing periodic or continuous monitoring of equipment conditions, in order to predict when maintenance should be performed.

This type of maintenance usually is integrated with the Internet Of Things (IoT). Our engineering team is able to support for RETROFIT of some furnaces through extensive discussion and consultation with PES Engineers, such as for SMART MANUFACTURING.

While for a new furnace, our furnace partner: IPSEN is able to supply a furnace equipped with PDMetrics(R) Software.

Why Furnace Preventive Maintenance is Necessary ?

Preventive Maintenance

Many customers may never think about the necessity of Preventive Maintenance as they will have an overhaul at the end of the year or repair the furnace when it is broken, but what they do not know is that this proactive action of Preventive Maintenance for your furnace is very beneficial for your furnace maintenance team. So, the benefit of our PM Packages are:

  • Avoiding Breakdown that can cause disruption in the production schedule
  • To make sure that parts for maintenance are always available or delivered on time
  • Avoiding unsatisfied customers due to the problem in the supply chain, that reduced your reliability.
  • Avoiding any accident or injury caused by furnace problems
  • Avoiding costly repair due to undetected & continuous furnace problems.

Scope of Preventive Maintenance

What Type of Furnaces ?

Furnace Model – Not Up to Scale
Furnace Sections for PM:
  1. Inlet
  2. Charge Vacuum
  3. Heating Zone
  4. Degassing Room
  5. Cooling Zone
  6. Discharge Vacuum
  7. Outlet
  8. Door 1, 2, 6, 7
  9. Gas Generator

Total Working Time: 8 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Overhead Crane supported by customer
  • Customer Supplying grease
  • Not Including Repair & Spare Parts
Furnace Model Not Up to Scale
Furnace Sections for PM:
  1. Entrace Chamber
  2. Drying Oven Zone
  3. Preheating & Brazing Zone
  4. Cooling Zone
  5. Exit Zone
  6. Mesh Belt & Driving Unit
  7. Control Panel

Total Working Time: 2 – 3 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Overhead Crane supported by customer
  • Customer Supplying grease
  • Not Including Repair & Spare Parts
Furnace Model Not Up to Scale
Furnace Sections for PM:
  1. Preheating Zone
  2. Heating Zone
  3. Cooling Zone
  4. Mesh Belt & Driving Unit
  5. Endothermic Unit Gas (DX Gas Generator)
  6. Control Panel

Working time: 7 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Overhead Crane supported by customer
  • Customer Supplying grease
  • Not Including Repair & Spare Parts
Furnace Model – Not Up to Scale
Furnace Sections for PM:
  1. Pre-washer
  2. Hardening Furnace
  3. Quenching Oil Tank
  4. Post – Washer
  5. Mesh Belt & Driving Unit
  6. Tempering Furnace
  7. Control Panel

Working time: 4 – 5 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Overhead Crane supported by customer
  • Customer to empty the quenching media
  • Not Including Repair & Spare Parts
Furnace Model Not Up to Scale
Furnace Sections for PM:
  1. Soaking Zone
  2. Cooling Zone
  3. Isothermal Zone
  4. Mesh Belt & Driving Unit
  5. Control Panel

Working time: 2 – 3 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Overhead Crane supported by customer
  • Customer to empty the quenching media
  • Not Including Repair & Spare Parts
Furnace Model not Up to Scale
Furnace Sections for PM:
  1. Loader Unit
  2. Heating Zone
  3. Quenching Oil Tank
  4. Exit Zone
  5. Control Panel

Working time: 3 – 4 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Overhead Crane supported by customer
  • Customer to empty the quenching media
  • Not Including Repair & Spare Parts
Furnace Model Not Up to Scale
Furnace Sections for PM:
  1. Pre-Heating Zone
  2. Heating Zone
  3. Cooling Zone
  4. Mesh Belt & Driving Unit
  5. Control Panel

Working time: 2- 3 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Customer to empty the quenching media
  • Not Including Repair & Spare Parts
Furnace Model not Up to Scale
Furnace Sections for PM:
  1. Pre-Heating Zone
  2. Heating Zone
  3. Cooling Zone
  4. Pusher Unit
  5. Control Panel

Working time: 2 – 3 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Customer to empty the quenching media
  • Not Including Repair & Spare Parts
Furnace Model not Up To Scale
Furnace Sections for PM:
  1. Loader Unit
  2. Entrance and Exit Zone
  3. Heating Chamber
  4. Control Panel

Working time: 1- 2 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Customer to supply overhead crane
  • Customer to empty the quenching media
  • Not Including Repair & Spare Parts
Furnace Model not Up to Scale
Furnace Sections for PM:
  1. Loader Unit
  2. Pre-Heating Zone
  3. Heating Zone
  4. Quenching Water Tank
  5. Control Panel

Working time: 3- 4 Days

Required Working Condition:
  • Stop the Furnace
  • Furnace temperature should be below 50 C
  • No Load
  • Customer to empty the quenching media
  • Not Including Repair & Spare Parts

For more detailed information on PM Package, click here: