The end of the year is fast approaching, which makes it an excellent time to take stock of all your equipment, and ensure everything is running at peak efficiency. What’s more, the festive period can sometimes see slightly reduced production schedules, making it a particularly useful time to perform crucial maintenance tasks before the new year kicks off. Not only does it help give you some peace of mind, but conducting thorough checks and addressing any potential issues now can also help to prevent costly downtime, and ensures that your systems continue to perform well in the coming months.

As one of the UK’s leading suppliers of a variety of factory automation equipment, such as programmable logic controllers and variable speed drives, we’ve got a couple of top tips on some of the best areas to review during your end of year checklist. Here’s what we’d suggest.

Check system performance and reliability

One of the first steps in your end-of-year maintenance routine should always be to assess the performance and reliability of your automation systems. This includes reviewing system logs, performance data, and any alerts or warnings from the past year.

It’s a good idea to pay particularly close attention to any recurring issues or anomalies that may have developed, even if they seemed minor at the time. Identifying patterns in system behaviour can help you pinpoint areas that might require further attention or upgrades. (To be honest, the same goes for human behaviour too – it can help to indicate if there are any machines or systems that aren’t doing their job quite as efficiently as they should be.) While you’re on with it all, it’s also a good time to test backup systems and verify that all fail-safes are operational, so you're prepared for any unexpected disruptions.

Inspect mechanical components and systems

The next step is to take a more detailed look at the mechanical elements of your automation equipment. Over time, wear and tear can take a toll on components like motors, drives, conveyors, and gears. As any experienced operations manager knows, the importance of a part isn’t necessarily indicative of how important it is – even though they’re relatively small, these parts are often vital for the smooth operation of certain systems, and any degradation could lead to unplanned downtime or costly repairs.

To avoid that, it’s a good plan to carefully inspect all moving parts for signs of damage, such as cracks, fraying, or misalignment, and check for lubrication levels and replace any worn-out seals or bearings. It's also important to clean and maintain air filtration systems to ensure they are functioning properly.

Review electrical systems and wiring

Your electrical systems are obviously the backbone of automation, so they’re definitely not one to be missed. It’s always best to start by inspecting all wiring for any signs of wear or damage. This includes checking for exposed wires, frayed cables, or any areas where corrosion may have occurred.

Over time, vibrations and environmental factors can cause electrical components to degrade – especially in more intensive environments – so now is the perfect time to replace any faulty parts. Electrical panels also need to be clean and free from dust or debris, which could cause overheating or short circuits. Don't forget to check the functionality of sensors, relays, and any other critical components that play a role in your automation processes. (You’ll likely be the one best positioned to know what all of them are!)

Update software and firmware

This is one that a lot of people miss, but staying up to date with software and firmware updates is essential to keep your systems secure and running smoothly. So then, take care to review any software updates or patches released by your equipment manufacturers throughout the year, and apply them if necessary. These updates can improve performance, fix bugs, and address security vulnerabilities. If your system has been running for a while without an update, this may be a good time to ensure everything is up to date. While you’re at it, you can review your system’s configuration settings to ensure that they are still aligned with your current production needs and safety protocols. That all should go a long way to ensuring that your systems are ready for the demands of the new year.

Plan for spare parts and inventory

Finally, take the time to review your spare parts inventory and order any components that may be running low or are likely to wear out in the near future. Having critical parts on hand can prevent production delays in the event of unexpected failures. Check the condition of any stored parts to ensure they haven’t deteriorated while in storage. If you’ve experienced issues with certain components throughout the year, consider replacing them pre-emptively to avoid further disruptions. And of course, it's also a good idea to review the suppliers and lead times for key parts to ensure you're prepared for the upcoming year’s requirements.

Those are all the key bases covered! Depending on the scale or nature of your operations, there may well be additional elements that you’ll need to cover to ensure that you hit the ground running in 2025. We’ll leave the specifics of those up to you.

As for us, you rely on our team to stick to what we do best; with more than two decades of experience here at LED Controls, we supply a wide range of components, including Programmable Logic Controllers, variable speed drives, and Motor Control Gear equipment – many sourced from globally-renowned manufacturers, including IMO and ABB. Feel free to look at what we’ve got available, and if you have any questions or need any advice, you can always give us a call on 01706 242050. We’re here to help!