Course Title: Machinery Maintenance & Troubleshooting for Packaging Professionals
Duration: 2 Days (6 hours per day)
Course Objectives:
This course is designed to equip packaging professionals with: A solid understanding of key packaging machinery (extruders, laminators, printing presses, slitters) Practical knowledge of preventive, predictive, and corrective maintenance Troubleshooting skills for mechanical, electrical, and automation systems Adherence to safety protocols and compliance standards Efficiency in reducing downtime and increasing operational productivity
Target Audience:
- Maintenance Engineers & Technicians
- Production Supervisors & Machine Operators
- Plant & Operations Managers
- Quality Assurance & Safety Officers
Course Details
Day 1: Fundamentals of Machinery Operation, Maintenance & Safety
Session 1: Overview of Key Packaging Machines (1 hour)
- Introduction to Extruders, Laminators, Printing Presses, Slitters, and Pouching Machines
- Functionality, key components, and role in packaging production
- Latest advancements in automation and smart manufacturing
Session 2: Machinery Operation Procedures & Best Practices (1.5 hours)
- Standard Operating Procedures (SOPs) for efficient machine handling
- Startup and shutdown procedures to minimize wear and tear
- Machine calibration and optimization for high-quality output
Session 3: Maintenance Strategies & Scheduling (1.5 hours)
- Preventive Maintenance – Routine inspections, lubrication, calibration
- Predictive Maintenance – Use of sensors, IoT, and AI-based monitoring
- Corrective Maintenance – Handling unexpected breakdowns efficiently
- Case study on maintenance planning and execution
Session 4: Safety Procedures & Compliance in Packaging Machinery (1.5 hours)
- Personal Protective Equipment (PPE) and workplace safety
- Lockout/Tagout (LOTO) procedures to prevent accidents
- Emergency response planning for machinery failures
- Compliance with ISO, OSHA, GMP, and industry safety standards
Session 5: Common Mechanical Issues & Troubleshooting (0.5 hour)
- Identifying wear & tear in belts, gears, bearings, and rollers
- Diagnosing misalignment, vibration, and noise problems
- Case study on mechanical failures and their solutions
Day 2: Troubleshooting, Advanced Maintenance & Performance Optimization
Session 6: Common Electrical & Automation Issues & Solutions (1.5 hours)
- Understanding PLC, sensors, motors, and drives
- Diagnosing power supply issues, wiring faults, and circuit breakdowns
- Smart troubleshooting with diagnostic tools and software
Session 7: Root Cause Analysis (RCA) for Machinery Failures (1 hour)
- Step-by-step RCA methodology
- Identifying recurring issues and their long-term solutions
- Case studies on real-world failure analysis
Session 8: Periodical Maintenance Planning & Spare Parts Management (1.5 hours)
- Creating a preventive maintenance schedule (weekly/monthly/yearly)
- Managing critical spare parts inventory to reduce downtime
- Digital tracking of maintenance logs and performance reports
Session 9: Energy Efficiency & Cost Optimization in Packaging Machinery (1 hour)
- Reducing power consumption and increasing machine lifespan
- Using AI & IoT-based predictive maintenance for cost savings
- Implementing lean maintenance techniques
Session 10: Troubleshooting Drills & Hands-on Case Studies (1 hour)
- Live simulation of machinery failure scenarios
- Group discussions on best troubleshooting techniques
- Q&A and expert advice on real-world maintenance challenges
Key Takeaways:
Comprehensive understanding of packaging machinery operations Proven troubleshooting techniques for mechanical & electrical failures Implementation of preventive & predictive maintenance strategies Improved workplace safety and compliance knowledge Optimized machine efficiency and reduced downtime