Robotics Maintenance

Rapid Response

Troubleshooting & Support

Real-time fault diagnosis and rapid resolution to keep your production lines running without costly unplanned stoppages.

Real-time Fault Diagnosis

Expert onsite fault diagnosis using robot controller logs, alarm history analysis, and systematic troubleshooting methodology.

Electrical, mechanical & software failure identification
Controller log analysis & alarm history review
Systematic root-cause methodology

Error Handling & Debugging

In-depth debugging of robot program errors, communication faults, and motion exceptions with full controller parameter optimisation.

Program error & motion exception resolution
Alarm code debugging & recovery routines
Communication fault diagnosis

Production Line Resolution

End-to-end troubleshooting of production line issues including robot-to-robot synchronisation, PLC faults, and peripheral malfunctions.

Robot-to-robot synchronisation problems
PLC communication & interface faults
Sensor faults & peripheral device issues

Emergency Breakdown Support

Priority emergency response for critical production stoppages. Engineers deployed rapidly with pre-loaded diagnostic tools for first-visit fix.

24/7 emergency callout availability
Rapid dispatch with OEM spare parts
Production restart with minimal downtime

Remote Diagnostics

Remote access troubleshooting via secure VPN connections to robot controllers for rapid preliminary fault assessment and resolution.

Secure VPN controller access
Real-time controller log monitoring
Reduced onsite response time

Root Cause Analysis

Comprehensive RCA for recurring faults. Detailed investigation reports with corrective and preventive action plans to eliminate repeat failures.

Structured fault investigation reports
Corrective action planning (CAPA)
Recurring failure elimination strategies

Preventive Maintenance

Scheduled Preventive Programs

Our OEM-compliant maintenance schedules are tailored to each robot model's requirements — covering all mechanical, electrical, and software checks to keep your fleet running at peak performance and avoid unplanned downtime.

From periodic robot health checks and grease replenishment to battery replacement, cable harness inspection, and controller cooling maintenance — every service is documented and tracked so you always know the health status of your robotic assets.

We also offer advanced calibration services including robot mastering, TCP validation, payload identification, and absolute accuracy calibration with laser tracker — ensuring every robot performs to its original factory specifications.

Periodic robot health checks (mechanical, electrical, software)
Grease replenishment and gear reducer maintenance
Battery replacement and backup verification
Cable harness inspection and dress pack servicing
Robot mastering and zero-point calibration
TCP (Tool Center Point) calibration and validation
Payload identification and inertia optimisation
Brake testing and motor current monitoring

Schedule a Maintenance Plan

Breakdown & Corrective

Rapid Breakdown Response

When production stops, every minute counts. Our emergency breakdown support ensures rapid engineer dispatch with pre-loaded diagnostic tools and genuine OEM spare parts — maximising first-visit fix rates and minimising costly downtime.

Our corrective maintenance capabilities cover motor replacement, gearbox repair, controller board and teach pendant repair, cable harness restoration, and full post-repair testing and validation. We source genuine OEM parts to ensure every repair meets factory specifications.

Beyond reactive repairs, we offer predictive maintenance programs using vibration analysis, thermal imaging, motor current monitoring, and IoT-enabled real-time robot health tracking — alerting you to anomalies before they become production-stopping failures.

Motor replacement and gearbox repair
Controller board and teach pendant repair
Cable harness restoration
Genuine OEM spare parts sourcing
Vibration analysis and thermal imaging
IoT-enabled real-time robot health tracking
Anomaly alerts before production stoppages
Full post-repair testing and validation

Request Emergency Support

Robot Breakdown Repair and Corrective Maintenance

What's Included

Comprehensive Maintenance Programs

Our OEM-compliant maintenance schedules are tailored to each robot model's requirements — covering all mechanical, electrical, and software checks to keep your fleet running at peak performance and avoid unplanned downtime.

Scheduled Preventive Maintenance Periodic health checks, grease replenishment, battery replacement, cable harness inspection, controller cooling maintenance, and brake testing.
Health Check & Calibration Robot mastering, TCP calibration, payload identification, absolute accuracy calibration with laser tracker, and repeatability benchmarking.
Breakdown & Corrective Maintenance Motor and gearbox repair, controller board and teach pendant repair, cable harness restoration, and genuine OEM spare parts sourcing.
Predictive Maintenance Vibration analysis, thermal imaging, motor current monitoring, IoT-enabled real-time tracking, and data-driven maintenance scheduling.

Worker Protection

Safety & Compliance

Comprehensive robot safety services ensuring worker protection and full regulatory compliance with ISO 10218 and TS 15066.

Robot Safety Checks

Complete safety system verification with documented audit reports for full compliance records.

Emergency stop circuit verification
Safety controller validation
Light curtain & safety mat functionality testing
Documented safety audit reports

Operator Safety Measures

Implementation of operator safety protocols ensuring every person working near robot cells is fully protected.

Safe work procedure development
Lockout/tagout (LOTO) verification
PPE requirements & safety zone marking
Operator safety induction programs

Safety Interlocks & Compliance

Interlock verification and full compliance with international and regional industrial safety standards.

Access gate & perimeter guarding verification
Dual-channel safety circuit validation
Compliance with ISO 10218 & ISO/TS 15066
HRC (human-robot collaboration) zone setup

Our Approach

Maintenance Workflow

A structured, proven approach from initial assessment to ongoing support — ensuring every robot performs reliably.

01

Fleet Assessment

We begin with a comprehensive audit of your entire robot fleet — reviewing maintenance history, fault logs, performance data, and OEM service requirements.

Complete fleet health audit
Fault history and alarm analysis
Performance baseline measurement

02

Maintenance Plan Design

We design a customised maintenance schedule aligned to OEM requirements, production cycles, and your operational priorities — with clear cost transparency.

Customised maintenance schedule
Spare parts inventory planning
Cost and resource forecasting

03

Scheduled Execution

Our certified engineers execute all maintenance tasks on schedule — preventive, predictive, and corrective — with minimal production disruption.

Onsite certified engineering team
Genuine OEM spare parts
Real-time progress communication

04

Monitoring & Optimisation

Continuous monitoring through IoT sensors and regular health reviews ensures emerging issues are caught early and maintenance schedules are continuously optimised.

IoT-enabled real-time health tracking
Quarterly performance review reports
Schedule optimisation based on data

Brands We Service

Multi-Brand Maintenance Expertise

Our engineers are certified across all major industrial robot brands — your fleet, our expertise.

ABB

KUKA

FANUC

Yaskawa

Nachi

Kawasaki

Staubli

Universal Robots

Omron

Epson

Denso

Comau

Key Capabilities

What Sets Us Apart

Multi-Brand SupportFanuc, ABB, KUKA, Yaskawa & more

Rapid ResponseEmergency breakdown support 24/7

Minimised DowntimePreventive & predictive strategies

Improved EfficiencyOptimised robot health & performance

Safe OperationsISO compliant safety audits

AMC PackagesFlexible annual maintenance contracts

OEM CertifiedGenuine parts & trained engineers

24/7 Support365 days a year

Full DocumentationService reports & as-builts

Operator TrainingTheory & hands-on programs

Proven Results

Case Studies

Real challenges. Real maintenance. Real results.

FANUC & KUKA Fleet Maintenance Program

Tier-1 Automotive Supplier

Challenge: Unplanned stoppages averaging 12 per month. Solution: Implemented customised preventive maintenance schedule with quarterly health audits and predictive monitoring.

Result: 60% reduction in unplanned stoppages within 6 months.

Emergency Breakdown Recovery

Metal Fabrication Plant

Challenge: Critical robot gearbox failure halting production. Solution: Engineer dispatched within 2 hours with replacement gearbox and full recalibration equipment.

Result: Production restored within 6 hours of initial call.

Safety Compliance Audit & Upgrade

Food & Beverage Manufacturer

Challenge: Non-compliant robot cell safety systems. Solution: Full safety audit, interlock redesign, light curtain installation, and ISO 10218 validation.

Result: Full compliance achieved with zero production downtime during upgrade.

Client Feedback

What Our Clients Say

"Prime's maintenance team has been looking after our Fanuc and KUKA fleet for two years. Their preventive schedules have cut our unplanned stoppages by over 60%. When we do have a breakdown, they're on-site within hours — usually fixed the same day."

— Maintenance Manager, Tier-1 Automotive Supplier

Industries Supported

Trusted Across Every Sector

Our maintenance engineers have experience servicing robotic systems across manufacturing's most demanding environments.

Automotive & Tier-1

Manufacturing

Industrial Automation

Food & Beverage

Pharmaceutical

Metal Fabrication

Warehousing & 3PL

Electronics Assembly

Common Questions

Frequently Asked Questions

What robot brands do your maintenance engineers support?

Our engineers are certified across all major industrial robot brands including ABB, KUKA, FANUC, Yaskawa/Motoman, Nachi, Kawasaki, Staubli, Universal Robots, Omron, Epson, Denso, and Comau. We service both traditional industrial robots and collaborative robots (cobots).

How quickly can you respond to an emergency breakdown?

We offer same-day onsite response for metro and regional areas, with remote troubleshooting available immediately. Our 24/7 emergency support line ensures you can reach an engineer whenever you need us — 365 days a year. Engineers are dispatched with pre-loaded diagnostic tools and common spare parts for first-visit fix.

What's included in a preventive maintenance visit?

Each preventive maintenance visit covers mechanical checks (grease, backlash, wear), electrical inspections (cables, connectors, batteries), software reviews (controller logs, alarm history), calibration verification (mastering, TCP), and safety system testing. Every visit concludes with a detailed service report and recommendations.

Do you offer annual maintenance contracts (AMCs)?

Yes. We offer flexible AMC packages tailored to your fleet size, robot brands, production schedule, and budget. AMCs include scheduled preventive maintenance visits, priority emergency response, discounted spare parts, and comprehensive documentation. We'll recommend the right package based on your specific needs.

Do you use genuine OEM spare parts?

Absolutely. We source and install genuine OEM spare parts for all repairs and replacements — ensuring every repair meets factory specifications and maintains your warranty validity. We maintain relationships with authorised distributors for rapid parts availability.

Can you help with robot safety compliance audits?

Yes. We specialise in robot safety audits and compliance with ISO 10218 and ISO/TS 15066. Our services include emergency stop circuit verification, safety controller validation, light curtain and safety mat testing, access gate and perimeter guarding verification, and full documented safety audit reports.