Diagnostics of Production Machines and Assessment of the Condition of Automation Components

Diagnostics of Production Machines and Assessment of the Condition of Automation Components

Purpose of the service

We offer comprehensive diagnostics of production machines, the purpose of which is:

• Early detection of wear and tear of automation and mechanical components,
• Prevention of failures and unplanned downtime,
• Optimizing maintenance plans,
• Increasing the reliability and efficiency of machines.
• Our activities allow for a full assessment of the technical condition of the machine in real time and prediction of when maintenance will be required.

Scope of diagnostics

Diagnostics includes analysis of the technical condition of key automation components and actuators, including:

Electric motors and drives – measurement of vibrations, currents, and temperatures, analysis of servo drives and inverters,

PLC controllers and I/O modules – communication integrity checks, system log analysis,

Sensors and encoders – verification of signal stability and real-time response,

Pneumatic and hydraulic systems – pressure, flow, and leak measurements,

Gears and bearings – analysis of vibrations, noise, and operating temperatures.

Diagnostic methods

• We use modern diagnostic methods, combining classic measurements with real-time data analysis:
• Periodic diagnostics
• Vibration, temperature, and noise measurements,
• Thermal imaging of components,
• Oil and lubricant analysis,
• Verification of the correct operation of control systems.
• Continuous diagnostics
• 24/7 monitoring of operating parameters,
• Analysis of wear trends (vibration, current, temperature),
• Use of AI and machine learning algorithms to predict failures,
• Integration with SCADA, MES, and CMMS systems.

Results and reporting

After the diagnostics are completed, the customer receives a detailed technical report containing:

• an assessment of the condition of the machine and its key components,
• technical indicators (including OEE, MTBF, MTTR, Health Index),
• recommendations for maintenance and replacement of worn parts,
• wear trends over time and a forecast for further operation.

The report can be prepared in the form of:

1. a PDF document,
2. an Excel spreadsheet (for further analysis),

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