Maintenance after shutdown, followed by maintenance before and during restart, is essential to ensure that production lines run smoothly during the summer shutdown period.
In our article, we show you what critical steps you should not miss as a maintenance technician, whether you are an expert who knows everything there is to know or an enthusiastic beginner to the production line, if you don’t want to start the season with a 3-week downtime.
The impact of downtime on machines – invisible damage
At the end of summer, not only do vacations come to an end, but factory shutdowns also end, and maintenance comes back into the spotlight. Those few days or weeks when the machines were idle did not pass without incident – physics and chemistry were at work, just invisibly. Condensation may have settled in the bearings, lubricants may have separated, seals may have deformed, and belts and chains may have stretched or tightened due to temperature fluctuations. Machines do not like immobility, especially in summer, when humidity, dust, and heat combine to silently wear down stationary parts.
Basic maintenance steps after shutdown
1. Assessing the condition of bearings: it is not enough to just look at them
Maintenance after shutdown is not an administrative necessity, but one of the most critical steps for the smooth continuation of production. An experienced maintenance technician can hear from a distance if something is wrong with a shaft, but the devil is in the details. It is not enough to visually inspect bearings: you have to turn them by hand and listen for the slightest tightness or clicking. If possible, a stethoscope or thermal camera can also help reveal problems before they lead to production downtime.
2. Proper lubrication – not too much, not too little
Lubrication is a separate art. After a shutdown, many younger maintenance technicians tend to lubricate “by eye,” but in such cases it is worth thoroughly cleaning the lubrication channels and not overdoing the amount of grease. Over-lubrication can destroy a bearing just as much as running it dry.
3. Drives, chains, belts – what to check before moving
Drive systems – V-belts, chains – should be inspected not only for tension but also for cracks and microcracks, especially if the machine has been standing in a wet, humid environment.
4. Electrical systems: dust, contacts, voltage
On the electrical side, the inside of control cabinets is often dustier than the corner behind the machine room. After shutdown, it is worth cleaning the connections with contact spray and measuring the voltage stability at the main points, especially in the case of frequency converter systems.
5. Compressed air – the silent source of loss
This is when microcracks and small leaks appear in the compressed air network, which should be detected with soapy water or an ultrasonic detector before performance slips unnoticed.
6. Maintenance of warehouse reserves – what stands ages
Many people forget about spare parts. Bearings, seals, and belts stored in the warehouse also age: if the room was damp, the seals may have hardened, the grease may have solidified, and the surface of the bearings may have become micro-rusty. Before installing anything that is not brand new, it is worth taking a closer look – many machines have broken down due to “new” parts that have been stored for too long.
Restart gradually – do not overload the machines
Temperature, lubrication, vibration: the “awakening” of machines
Never start the restart at full load. During the first start-up, allow the machine to reach its temperature, the parts to settle, the lubricant to spread, and the vibration to reach its normal operating level. In this case, thermal imaging or a quick vibration diagnosis can be useful, especially if you want to take baseline measurements for future comparisons.
Human factors and software pitfalls
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Operator experience: the best fault indicators
Experienced maintenance technicians pay attention not only to the machine but also to the operator. If someone heard a strange noise before the shutdown or felt an unusual vibration, it is worth mentioning it now. The best fault detections do not always come from instruments, but start with a well-formulated intuition such as, “Hey, it doesn’t usually make that noise…”
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Automation and sensors – when an update is missed
It is equally important that not only the machines but also the software wake up properly. Automated systems, PLCs, and sensor networks often require updates or have lost a setting during downtime. Many a restart has gone off the rails because the sensor “didn’t see” the incoming product or the robot arm’s position slipped a few millimeters.
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Rehearsing emergency scenarios
Even the most professional plants can fit in a short emergency drill at this point—if nothing else, just going over who does what if something smokes, jams, or doesn’t behave as it should. This is especially useful for new employees, but even the more experienced ones are sometimes surprised when a forgotten stop button turns up.
The role of documentation in preventing future errors
Last but not least: document everything. Not out of an obsession with administration, but so that we don’t make the same mistakes next year. If we now see that a particular bearing always causes problems after a shutdown, we may need to use a different type or lubricant. If a particular drive stretches every year, we may need to rethink the entire design. Documentation is not for the sake of paperwork – it is for the sake of the next successful restart.
Post-shutdown maintenance as a strategy – not just an obligation
One thing is certain: the period after the summer shutdown is not only a risk, but also an opportunity. An opportunity to strengthen our systems and prevent mistakes that could cost millions in real life. If we do all this in a systematic way, paying attention and helping each other, then not only the machines but also we ourselves will get off to a smoother start – every year. Maintenance is not only necessary but also a strategic step – especially after shutdowns, when every detail counts.
How to perform factory maintenance after the summer shutdown?
Here is the 15-step list, as promised:
✅ Manual rotation of bearings, checking for noise and tightness
✅ Stethoscope or thermal camera bearing diagnostics (if available)
✅ Cleaning lubrication channels, applying the correct amount of grease
✅ Visual inspection of drives (belts, chains), checking for tension and cracks
✅ Dusting control cabinets, cleaning contact surfaces
✅ Measuring voltage stability in frequency converter systems
✅ Checking the compressed air network for leaks
✅ Inspecting the condition of warehouse bearings and seals before installation
✅ Restarting the machine gradually, without full load
✅ Thermal imaging or vibration diagnostic measurements during the initial period
✅ Consultation with operators: whether there were any unusual noises or vibrations previously
✅ Checking automated systems, sensors, PLCs, searching for updates
✅ Repeating emergency procedures, training new employees
✅ Documenting all maintenance steps
✅ Preparing for the next maintenance cycle
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If you have any questions, please feel free to contact our expert colleagues!
