Plant Machinery Maintenance Checklist: Importance of Safety & Tips for Optimal Performance

Plant machinery is the backbone of any construction or industrial project. It’s crucial to keep the machinery in optimal condition to prevent costly downtime, worker injury, or equipment damage. To ensure plant machinery runs efficiently, it’s essential to carry out regular maintenance checks.

In this blog, we will provide an extensive checklist for plant machinery maintenance and highlight the importance of safety.

Why is plant machinery maintenance important?

Regular maintenance of plant machinery is crucial for many reasons. The primary purpose of maintenance is to ensure the safe operation of machinery. Regular maintenance helps to identify and address any mechanical issues that may compromise the safety of workers on the job site. In addition to safety concerns, regular maintenance helps to ensure optimal performance, increased longevity of the machinery, and reduced downtime.

Many regulatory agencies require companies to maintain their machinery according to strict guidelines. Companies that fail to comply with these regulations may face fines, legal action, and even the suspension of operations. Regular maintenance can help companies stay in compliance and avoid these costly consequences.

Heavy machinery operators are exposed to numerous hazards, and any unexpected failure can result in injury or even death. Regular maintenance and inspections can identify and address potential safety issues before they become accidents.

Importance of safety in plant machinery maintenance

The safety of workers should be a top priority when performing plant machinery maintenance.

The following safety measures should be taken:

  • Always wear appropriate personal protective equipment, such as safety glasses, gloves, and hard hats.
  • Make sure the machinery is turned off before performing any maintenance checks or repairs.
  • Secure the machinery to prevent accidental startup or movement during maintenance.
  • Use proper tools and equipment for the job and follow the manufacturer’s instructions.
  • Use lockout/tagout procedures to prevent unexpected startup or movement of the machinery.
  • Follow proper lifting techniques to prevent injury when lifting heavy machinery components.
  • Have a first aid kit and an emergency plan in place in case of an accident.
Plant Machinery Maintenance Checklist

What is a plant machinery maintenance checklist?

A plant machinery maintenance checklist is a tool that operators use to inspect and identify issues that may arise during the operation of plant machinery. A well-designed plant machinery maintenance checklist covers all aspects of the machinery, including electrical, mechanical, hydraulic, and pneumatic components. It helps to ensure that all components are in good condition and functioning correctly.

Plant Machinery Maintenance Checklist

1. Electrical system

The electrical system of plant machinery should be checked periodically to ensure it’s in optimal condition. The following tasks should be performed:

  • Check for loose connections, frayed wires, and damaged insulation
  • Inspect the battery for signs of corrosion and ensure it’s adequately charged
  • Test all lights, signals, and alarms to ensure they are functioning correctly
  • Check the alternator, starter motor, and voltage regulator for proper operation.

2. Engine system

The engine is the heart of the plant machinery, and its maintenance is critical to the machine’s optimal performance. The following tasks should be performed:

  • Check the engine oil level and top it up if necessary
  • Inspect the air filter and replace it if dirty
  • Check the fuel filter and replace it if needed
  • Check the coolant level and inspect the radiator and hoses for leaks
  • Inspect the fan belt for signs of wear and tension.

3. Hydraulic system

The hydraulic system of plant machinery is responsible for powering most of the equipment’s functions. The following tasks should be performed:

  • Check the hydraulic fluid level and top it up if needed
  • Inspect all hoses and connections for leaks and damage
  • Check the hydraulic pump and motor for proper operation
  • Test the pressure relief valves and other safety devices.

4. Pneumatic system

The pneumatic system of plant machinery is responsible for powering some of the equipment’s functions. The following tasks should be performed:

  • Check the air compressor and ensure it’s properly lubricated
  • Inspect all hoses and connections for leaks and damage
  • Check the air filter and replace it if necessary
  • Test the pressure relief valves and other safety devices.

5. Mechanical system

The mechanical system of plant machinery includes all moving parts, such as gears, bearings, and belts. The following tasks should be performed:

  • Inspect all moving parts for signs of wear and damage
  • Lubricate all moving parts as recommended by the manufacturer
  • Check the brakes and brake pads for wear and adjust them if necessary
  • Test the steering and suspension systems.

Below: Digital Plant Machinery Maintenance Checklist by DIGI CLIP mobile forms

Plant Machinery Maintenance Checklist

DIGI CLIP mobile forms provide digital safety, compliance & inspections checklists

Best Practices for Plant Machinery Maintenance

To ensure that plant machinery maintenance is effective, it’s important to follow best practices. Here are some tips to keep in mind:

1. Create a maintenance schedule

Develop a maintenance schedule that outlines the tasks that need to be performed and when they should be completed. This schedule should take into account the manufacturer’s recommendations, regulatory requirements, and the equipment’s usage.

2. Train employees

Ensure that all employees who are responsible for maintaining the plant machinery are properly trained on the maintenance tasks they need to perform. They should also be trained on safety procedures and the proper use of tools and equipment.

3. Keep records

Keep detailed records of all maintenance tasks performed, including the date, the person who performed the task, and any issues identified. This information can be used to track trends, identify recurring issues, and improve the maintenance process.

4. Conduct regular inspections

Regular inspections should be conducted to identify any issues before they become problems. Inspections should be conducted by trained employees who know what to look for and how to identify potential safety hazards.

5. Use the right tools

Make sure that employees have access to the right tools and equipment to perform maintenance tasks. Using the wrong tools can cause damage to the machinery and create safety hazards.

6. Have a backup plan

In the event that a piece of machinery fails unexpectedly, it’s important to have a backup plan in place. This may include having spare parts on hand or having a backup piece of machinery that can be used in the event of a failure.


Regular plant machinery maintenance is essential for ensuring the safety of workers and the optimal performance of the equipment. A well-designed plant machinery maintenance checklist can help to identify and address any mechanical issues before they become problems. By following best practices, companies can ensure that their plant machinery is well-maintained, in compliance with regulations, and operating at peak efficiency.

DIGI CLIP mobile forms – What Do We Do?

DIGI CLIP mobile forms is an easy-to-use inexpensive digital checklist & inspection app and cloud-based software. DIGI CLIP is used across different industries to capture safety and compliance data and other information to help improve safety, compliance and operational efficiencies.

DIGI CLIP will allow you to remove paper reporting from your business – no more lost, late missing or illegible checklists. The DIGI CLIP mobile app allows images, comments and digital signatures to be added to checklists from a phone or tablet.

DIGI CLIP has a Form Library where you can access all of your checklists, inspections and more ready for use. All checklists and inspections can be edited or updated to meet your risk and operational requirements.

DIGI CLIP also has a safety management module called Safety Tracker. Safety Tracker is our incident and hazard reporting and management software application that adds to DIGI CLIP mobile forms. Incidents and hazards are reported via the DIGI CLIP app or directly on the cloud-based software. Incident and quality Investigations and hazard assessments are completed on templates provided by DIGI CLIP and corrective and closeout actions are tracked by the cloud-based software.

Follow this link if you want to know more about what we do and how we can help or send us a message.

Streamline your safety, compliance & inspection checks with the DIGI CLIP mobile checklist app today.

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Disclaimer: The information contained in this article is for general informational purposes only. It is not intended to provide legal, financial, or other professional advice, nor is it intended to replace the advice of a qualified professional. The author and publisher disclaim any liability for any direct, indirect, or consequential damages arising from the use of or reliance on the information provided in this article. Readers are advised to seek the advice of a qualified professional for any specific concerns or questions related to their business operations or compliance with relevant regulations.