When it comes to industrial machine repair, many businesses focus only on fixing problems after they occur. But a more effective approach is to focus on preventative maintenance and regular servicing, which keeps machinery running smoothly and avoids costly downtime.
At DFW Movers & Erectors, we specialize in professional industrial machine repair and maintenance. From small 60-ton OBIs to massive 20,000-ton forging presses, our certified millwrights and technicians have the expertise to keep your operations running at peak efficiency. In this blog, we’ll cover common industrial machine issues, how preventative maintenance can prevent costly repairs, and what regular service with DFW Movers & Erectors can do for you.
Common Issues That Require Industrial Machine Repair
Industrial machinery is built to handle heavy workloads, but even the toughest equipment isn’t immune to wear, strain, or failure. Some of the most common problems include:
- Mechanical wear and tear such as abrasion, adhesion, corrosion, and fatigue. Over time, belts, bearings, and gears can wear down, leading to decreased efficiency or complete failure.
- Electrical problems, such as overheating motors, damaged wiring, or faulty connections, which can cause sudden shutdowns. Motors, wiring, and control panels are susceptible to short circuits and component burnout.
- Hydraulic or pneumatic system failures, often caused by leaks, pressure drops, or pump malfunctions that can halt production. This is important to pay attention to for machines that rely on fluid or air power.
- Issues with control systems, including faulty PLCs, sensors, or calibration errors that disrupt automation and accuracy. These issues can lead to operational errors, production defects, or unexpected downtime.
- Misalignment or poor calibration that can lead to uneven wear, reduced accuracy, and defects in production. Alignment and calibration issues can also lead to machine damage.
Left unchecked, these issues can result in unplanned downtime, expensive repairs, and reduced equipment lifespan.
How These Issues Can Be Prevented Through Regular Service
Implementing regular industrial machine maintenance as a proactive strategy can deliver tangible benefits for any operation. In fact, industry studies show that a significant majority of industrial machinery failures are preventable with proper preventative maintenance. In fact, it is reported that implementing strategic maintenance strategies can lead to a 60% decrease in maintenance costs and 40% improvement in equipment lifespan.
By scheduling consistent industrial machine maintenance, businesses can increase equipment efficiency, reduce costly downtime, extend the lifespan of machinery, and lower long-term repair expenses. Routine servicing also improves workplace safety by reducing the likelihood of all types of issues like mechanical failures, hydraulic leaks, or electrical malfunctions, while ensuring that production quality remains consistent.
In practical terms, this means that many common repairs, such as replacing a worn bearing, fixing a leaking hydraulic line, or recalibrating a misaligned press, can often be caught early and corrected before they lead to unplanned shutdowns or major breakdowns. Facilities that follow structured maintenance schedules often see fewer emergency repairs, lower repair costs, and improved overall equipment reliability.
The Benefits of Working with DFW For Your Industrial Machine Maintenance
At All Press Services (APS), a division of DFW Movers & Erectors, we specialize in preventative care that addresses problems before they escalate into failures. We combine these benefits with hands-on expertise to maximize machine performance:
Mechanical Wear
All Press Services ensures that all moving parts and contact surfaces are properly maintained to prevent wear-related performance loss. Our technicians apply specialized protective coatings, maintain precise lubrication schedules, correct alignment issues, and replace worn components before they affect operations. This proactive approach helps machinery operate efficiently for longer periods and reduces the likelihood of needing industrial machine repair later on.
Hydraulic and Pneumatic Systems
Our team conducts comprehensive inspections, pressure testing, and system tuning on hydraulic and pneumatic components. By monitoring pressure levels, checking for leaks, and ensuring pumps and valves operate at peak efficiency, we maintain smooth, reliable motion in presses, lifts, and other critical equipment. Preventative maintenance of these systems keeps production lines running steadily and avoids costly shutdowns.
Control Systems
We provide full evaluation, recalibration, and upgrades for PLCs, sensors, and automation controls. Our technicians ensure that all control systems are synchronized, accurately programmed, and operating at optimal efficiency. This includes testing system responses, updating software or hardware as needed, and implementing modern retrofits to improve machine reliability and precision.
Electrical Components
When it comes to industrial machine maintenance for electrical, our team inspects, tests, and services motors, wiring, and control panels to ensure reliable electrical performance. We identify potential hazards, replace failing components, and optimize power distribution to prevent outages or system failures. This work reduces downtime, improves safety, and extends the lifespan of electrical equipment.
Alignment and Calibration
We conduct full alignment of mechanical systems, recalibrate tonnage monitors, and verify that all machines, including presses, mills, and lathe, meet exact tolerances. Our team’s attention to detail maximizes efficiency, ensures consistent production quality, and reduces long-term wear on machinery.
With certified millwrights, expert technicians, and in-house custom part manufacturing, we provide complete solutions for presses, mills, lathes, brakes, shears, and other industrial machinery. No matter the size or complexity of your equipment, we deliver the industrial machine maintenance needed to keep it running reliably for years to come.
What is Considered Regular Service?
Regular service can vary depending on the type of equipment, usage demands, and manufacturer recommendations. At All Press Services, we tailor maintenance schedules to your specific operation to ensure your machinery gets the right level of care at the right time. A well-structured service plan typically includes daily, monthly, and annual tasks designed to keep your machines running at peak performance.
Daily or Weekly Checks
These are routine but critical steps that prevent small issues from becoming big problems. Our technicians focus on cleaning, lubrication, and visual inspections of critical components to catch signs of abrasion, leaks, or misalignment early. For example, making sure lubrication systems are filled and functioning helps prevent adhesion wear, while daily checks for leaks in hydraulic and pneumatic lines protect against sudden pressure drops. Even something as simple as monitoring temperature, vibration, and unusual noise can provide early warnings of mechanical or electrical issues.
Monthly or Quarterly Maintenance
This level of service provides a deeper dive into machine performance. Our technicians perform functional testing, recalibrate tonnage monitors, update lubrication systems, and verify alignment across critical components. Hydraulic and pneumatic systems are pressure-tested and inspected for wear, while electrical panels, motors, and controls are examined for faulty wiring, overheating, or component fatigue. By replacing worn parts proactively before they fail, we help you avoid costly, unplanned downtime. This stage is also where our ability to custom-manufacture replacement parts becomes invaluable, ensuring machines of any size or age can stay in service.
Annual Overhauls
Annual servicing is the most comprehensive form of maintenance. Our team conducts complete overhauls, including major part replacements, retrofitting outdated control systems, and restoring machines to factory-level performance standards. This may involve complete recalibration, full system alignments, advanced performance testing, and application of protective coatings to guard against corrosion. In some cases, annual service is also the time to integrate upgrades, such as new lube systems or advanced control monitoring, ensuring your equipment keeps up with evolving industry standards.
Get Started with Proactive Industrial Machine Repair and Maintenance
Industrial machine repair doesn’t have to be reactive. With a regular maintenance program from our expert All Press Services division, you can prevent expensive breakdowns, reduce downtime, and extend the life of your equipment. Our certified millwrights and technicians not only repair machinery, they provide proactive solutions, custom-manufactured parts, and expert care for presses, mills, lathes, and other industrial equipment.
By partnering with DFW Movers & Erectors on industrial machine maintenance, you’re investing in reliability, efficiency, and peace of mind for your business. Schedule a consultation today and let us take care of your industrial machinery, so you can focus on running your operations smoothly without surprises.