Experimental Investigation and Optimization of Preventive Maintenance Parameters for Reducing Machine Downtime in Manufacturing Industries

Machine downtime is one of the major factors affecting productivity, equipment utilization, and operational efficiency in manufacturing industries. This study presents an experimental investigation and optimization of preventive maintenance parameters for reducing machine downtime and improving reliability. Maintenance-related factors such as maintenance interval, inspection frequency, lubrication frequency, and cleaning schedule were analyzed using statistical techniques. Downtime records, breakdown frequency, MTBF, MTTR, availability, and productivity data were collected and evaluated before and after implementing an optimized preventive maintenance schedule. The results demonstrated a significant reduction in downtime and breakdown frequency, along with improvements in machine availability, reliability, and production output. Statistical analysis identified inspection and lubrication frequency as the most influential maintenance parameters. The proposed maintenance optimization approach offers a practical and cost-effective solution for enhancing equipment performance and productivity in small and medium manufacturing industries.