How Often Do You Need a Machine Alignment Inspection?

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How Often Do You Need a Machine Alignment

Inspection?
by George LeGrand on January 24, 2017 in Alignment Solutions, Industry Knowledge

One of the questions OASIS customers most often ask is “How often do I need to have my machine inspected
for alignment?”

Unfortunately, there isn’t a simple answer. There are a number of factors that can affect the alignment of
your equipment and these should be taken into consideration when creating a machine alignment inspection
plan at your facility. In this post, we provide the top three factors that can determine how often alignment
inspections are needed and discuss the reasons why there are no set rules that can be applied.

Type of Machine
Alignment inspection intervals can vary from machine to machine.  For a typical paper machine that runs
continually at standard operating speeds, alignment condition inspections should occur every 12 to 18
months – with sampling inspections conducted in each of the major sections – wet end, press, dryers,
calender and reel.

However, in today’s competitive environment, the majority of paper manufacturers are running up against
their speed thresholds in order to maximize production. This practice significantly shortens the alignment
inspection intervals – often from 6 to 9 months.

Printing presses and winders typically run at much faster speeds and require a greater degree of accuracy to
ensure maximum productivity. Because of this, these machines should be inspected more frequently.

Corrugators and some laminators

typically have “looser” optimal
operating tolerances, allowing them
to have a greater interval of time
between inspections.   

Age of Machine
A machine’s age has a direct effect
on how often an alignment
inspection should be performed. In
the case of a newly installed line,
one may think that the intervals
between alignment inspections could
be much longer. However, the
opposite is actually true. Alignment
OASIS metrology engineer uses a Leica AT960 laser tracker to
inspections are critical during initial
inspect wallboard process line.
operation with the largest factor
being foundation settling. When
installing a piece of production equipment on a new foundation, the foundation may not settle equally

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How Often Do You Need a Machine Alignment Inspection? Page 2 of 5

under the weight of the machine causing component movement. Shorter intervals between inspections can
capture that movement and allow you to make necessary adjustments. Shorter intervals between
inspections also allow you to monitor thermal expansion, operating vibration, frame movement and
mounting hardware issues.

Older machines are prone to worn bolts, elongated mount holes, and the tendency for increased vibration
from unbalanced components.  These issues all promote component movement.  Shorter intervals between
alignment inspections are needed in order to map the rate of alignment degradation.

Maintenance Practices
Typical predictive/preventive maintenance plans include vibration monitoring, gear clearance inspections,
component lubrication, and housekeeping. During maintenance downtime, it is sometimes also necessary to
reposition components such as rolls, drive components, bearings and couplings.

If component repositioning activities are accomplished without alignment best practices in place, the
overall alignment condition of the machine will degrade much more rapidly. This will require shorter
intervals between alignment inspections. Conversely, if alignment best practices are included as part of
your maintenance plan, not only will your machine run at optimal performance levels, but the longer the
intervals can be between alignment tune-ups.

Other Factors to Consider

Other factors that should be taken into consideration when creating a machine alignment inspection plan
include such things as the location of your facility (are you located in an earth quake and/or flood zone?)
and the age and condition of your manufacturing area or building. Harsh mill environments, building
settlement, and cracked or broken flooring will all have a direct effect on how often your machine should
receive alignment inspections. Even the type of product you run can have an effect on when and how often
your machine requires an alignment inspection.  

This post describes just some of the reasons why there are no set rules by machine as to when and how
often you schedule alignment inspections. By building a strong partnership with your alignment vendor, you
can work together to create an inspection plan that is best suited for your facility based on the machine and
your process, product specifications, production requirements, and your preventive maintenance plan.

If you would like a site visit by an OASIS representative to discuss an alignment inspection plan for your
machine, please contact us. Be sure to subscribe to our blog for regular updates on precision measurement
tools and technologies, industry knowledge, case studies and more. 

About George LeGrand

With almost 20 years at OASIS, George LeGrand has a broad range of
experience with all types of industrial manufacturing equipment. As an
Optical Engineer, George worked on paper machines, coater/laminators,
corrugators, printers and more. He is currently Account Manager for the Southeast Region.
View all posts by George LeGrand →

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