CNC Machine Tool Reliability

Ensuring reliability for CNC Machine Tools or any other rotating equipment can be a mind-
boggling experience for many of us. We may not be sure where to start or what specifically to
do. This uncertainty, along with a reactive environment, can cause us to delay putting into action
the required steps to help ensure reliable equipment. On the other hand, many of us tend to over
complicate or over think the necessary steps in ensuring reliability. We first spend days then
weeks and months trying devise the perfect maintenance plan. Before we know it, the simple
plan we had in mind turns into such a major undertaking that we lose the energy to put it into
action or come to find out that the required resources are unavailable.

It doesn’t have to be this way. The beginning steps in improving equipment reliability can and
should be simple while still effective. The following examples are three basic, but effective,
equipment level actions that can get you started on the path of ensuring reliability. Please keep in
mind that these three points are not intended to replace a fully implemented reliability program,
but intended to serve as a starting point to help assist those individuals who are not sure where or
how to start the journey.

Keep it Clean
CNC Machine Tools process a wide variety of materials, from metals to woods to plastics. Each
of these materials can engender a large amount of scrap such as, shavings, chips, dust and so on.
All of these byproducts of processing can and typically are contributors to equipment failures
such as coordinate system damage and tool head jams. CNC Machine Tools are also typically
operated in environments that do not meet the manufacturers recommendations. This includes
production areas that are not climate controlled and produce a high amount airborne
contaminates that can clog air filters and breather elements The good news is that it doesn’t take
a complicated plan to overcome this nuisances. Basic cleaning of the equipment on a regular and
thorough basis is a simple and effective method in helping ensure reliability.

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Reliability Tips:
• Post a daily or per shift cleaning checklist and schedule for each machine tool
• Train operators on the importance of cleaning
• Provide a set of clear and detailed cleaning instructions
• Train operators on the what, where, when, and how to clean the machine tool

Correct Set-up
CNC Machine Tools, like most rotating equipment, require a “set-up” or “start-up” before
production begins. For example, a CNC sheet metal punch press requires tooling to be set-up
before processing the material. This tool set-up requires sharpening and cleaning of the Punch
and Die, as well as selecting the proper die clearance and aligning the tool properly in the tool
holder. Excessive wear to the machine or component damage will occur if any one of these steps
are ignored or performed improperly. However, just as in the example above, the solution to
minimizing if not removing these potential hazards is simple. Training operators and providing
detailed instructions will help ensure that the machine is set-up correctly each and every time.

Reliability Tips:
• Post a set-up or start-up checklist for each machine tool
• Provide a set of clear and detailed instructions
• Train operators on the importance of correct machine tool set-up
• Train operators on the what, where, when, and how to set-up machine tool

Proper Operation
CNC Machine Tools have become exceptionally accurate and exceptionally quick during the last
decade. These advances in technology are allowing companies to provide higher quality products
in much shorter processing times. However, there is a downside to these benefits, if it can be
called a downside, with speed and accuracy comes precise operation. The days of “getting it
close” are forever gone. There is seldom any room for error with today’s CNC Machine Tool
capabilities. Indubitably, proper machine tool operation is a inevitable. This includes selecting
the proper buttons at the control panel to generating the CNC program to designing the product
to be produced. As identified in the previous two action items, a trained and knowledgeable

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©Life Cycle Engineering ®
workforce is a highly effective resource. Today, training is required not only for the operators of
the equipment but also the associates programming the equipment and product engineers who
determine what will be produced on the equipment. Each one of these groups needs a thorough
understanding of the machine capabilities, technical specification and operating parameters in
order to help ensure reliability.

Reliability Tips:
• Train Operators, Programmers and Application/Engineering personnel in regards to machine
operation, capabilities and specifications
• Provide an operating instruction manual at each machine
• Assign Programmers and Engineers to a day or two of operating the equipment to gain a
lucid understanding of the machine capabilities
• Assign the Operators to a day or two with the Programmers and Engineers to gain a clear
understanding of their functions and how they relate to machine operation

As you can see, getting started on the road to equipment reliability does not have to be
complicated. The implementation of these three basic practices will get you headed in the right
direction in ensuring reliable CNC Machine Tools. Just keep in mind that these proactive
measures are not intended to be the “end-all” in ensuring reliability. They are just the beginning!

For More Information:

Jeffrey Nevenhoven, CPMM
Life Cycle Engineering ®
843.412.1406
jnevenhoven@LCE.com

4360 Corporate Road • Charleston, SC 29405-7445 • 843.744.7110 • www.LCE.com

©Life Cycle Engineering ®