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Maintenance Audit Discovers Repairs that Decrease Batch Time by 2 Minutes

We received a request for a maintenance audit on a high volume meat processing line that is a supplier to fast food restaurant chains.  The first round of inspection uncovered several maintenance issues:

SYMPTOM
A Pump Feeder motor kept tripping the breaker and caused constant down-time.

RECOMMENDATION/REPAIR
The gearbox bearings were bad and was causing excess loading. The gearbox was replaced which fixed the issue. Reducing down-time for that Pump Feeder.

SYMPTOM
Mixers on the processing line did not pull sufficient vacuum.

RECOMMENDATION/REPAIR
Both mixers had multiple vacuum leaks through cracked welds, worn out seals, incorrect seals and improperly installed seals The seals were replaces and the cracked welds were repaired which allowed the unit to pull required vacuum 2 minutes faster, decreasing cycle times.

SYMPTOM
Inspection uncovered possible catastrophic failure of the agitators.  

RECOMMENDATION/REPAIR
Both mixers had agitators with cracked welds. They were repaired during scheduled maintenance.

SYMPTOM
Vacuum Stuffers were underperforming.

RECOMMENDATION/REPAIR
Two stuffers in the processing line were underperforming and producing poor quality product due to lack of vacuum. Both stuffers had worn out pumps that were rebuilt and worn out seals that were replaced.  These changes gave the processor a 28% increase in throughput out of the stuffer and better-quality product without air bubbles.

The cost for the maintenance audit, including a detailed report was $2000, plus travel expenses. The result was savings in energy, down-time, batch turnaround and overall increased production. This processor in fact, contracts with Mepaco every six months for a maintenance audit to avoid unplanned delays and to make sure their line is running as efficiently as possible.

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