Accurate reporting and documentation are essential for maintaining safe, reliable, and profitable roll forming operations. Whether your machine is producing roofing panels, purlins, decking, stud/track framing, or metal flashing, the electrical and mechanical systems must be monitored, measured, and documented correctly.

Machine Matcher provides industry-leading reporting and documentation services designed specifically for roll forming machines of every brand, size, and production capacity. Our reports give factory managers, maintenance teams, and machine owners the clarity they need to make informed decisions — from diagnosing faults to planning upgrades and preventive maintenance.

This guide explains the four core report types offered by Machine Matcher:

Service Report
Fault Diagnosis Report
Maintenance Checklist
Upgrade Recommendation Report

Each section shows what’s included, why it matters, and how it improves machine uptime, accuracy, and long-term performance.

1. Service Report

Clear documentation for every technician visit

Every on-site or remote service performed through Machine Matcher includes a fully documented Service Report. This ensures that all machine adjustments, repairs, calibrations, and inspections are professionally recorded.

What’s included in a Service Report

Machine details (brand, model, serial, profile type)
Description of work carried out
Electrical tests performed
Mechanical adjustments made
VFD/servo parameter changes
Sensor/encoder alignment work
Parts replaced or repaired
Before/after test results
Production performance verification
Technician name and contact
Recommendations for follow-up actions

Why it matters

A good service report creates a maintenance history that can be used to:

Track recurring issues
Monitor machine aging
Understand fault patterns
Improve long-term reliability
Protect warranty claims
Increase machine resale value

Machine Matcher provides consistent, standardized reports for clarity across all service visits.

2. Fault Diagnosis Report

Detailed analysis of machine failures, breakdowns & intermittent faults

When a roll forming line stops unexpectedly, the cause is not always obvious. Electrical faults, PLC errors, VFD instability, servo misalignment, or feedback sensor issues can all appear similar to operators.

Machine Matcher’s Fault Diagnosis Report provides a clear, step-by-step analysis of the issue — and exactly how to fix it.

What’s included in a Fault Diagnosis Report

Full description of symptoms
Fault history (PLC, VFD, servo, HMI)
Root cause identification
Photos of fault location
Thermal imaging (if required)
Panel inspection findings
Encoder/sensor test results
Mechanical alignment assessment
Power quality & grounding analysis
Required replacement parts
Corrective actions (with priority list)
Risk rating (low–high)

Why it matters

A professional diagnosis prevents:

Guesswork
Unnecessary part replacement
Extended downtime
Incorrect repairs
Repeated failures

The report also includes a written “Fix Plan” to guide technicians step-by-step on-site.

3. Maintenance Checklist

Routine & preventive tasks that extend machine life and reduce downtime

Machine Matcher provides one of the industry’s most comprehensive Maintenance Checklists tailored specifically for roll forming lines.

What’s included

Electrical Maintenance Checklist

Terminal tightening
PLC input/output testing
VFD/servo temperature check
Grounding system verification
Noise/harmonic analysis
Cable routing inspection
Sensor and encoder alignment
24VDC power stability

Mechanical Maintenance Checklist

Roll stand alignment
Bearing/lubrication check
Chain tension
Gearbox oil level
Punch/shear tool inspection
Hydraulic system pressure check

Safety Checklist

Emergency stop loop testing
Guard switch inspection
Overload relay testing
Lockout/tagout compliance

Why it matters

A structured maintenance checklist:

Prevents unexpected failures
Increases production uptime
Protects motors, drives, and tooling
Reduces scrap and rework
Extends machine lifespan
Improves safety compliance

Machine Matcher checklists are used by factories worldwide for routine and preventive scheduling.

4. Upgrade Recommendation Report

Modernizing old machines for higher performance and reliability

As machines age, production demands increase and electrical technology becomes more advanced. Machine Matcher provides a complete Upgrade Recommendation Report for factories wanting to improve reliability, speed, automation, or safety.

What’s included in an Upgrade Report

Electrical Upgrade Recommendations

PLC modernization
New touch-screen HMI
Servo/flying saw upgrades
VFD replacements
Panel rewiring
Noise & harmonic filtering
Encoder upgrades
Power supply replacement

Mechanical Upgrade Recommendations

New roll sets
Punching system upgrades
Flying shear re-alignment
New decoiler or automatic uncoiler
Hydraulic power unit upgrades

Automation Upgrade Recommendations

Remote diagnostics (Ewon/PLCRemote)
Automatic stacking
Automatic coil handling
Profile tracking sensors
Production data logging

Each recommendation includes:

Cost estimate
Expected performance improvement
Downtime required
ROI justification

Why it matters

Upgrades dramatically improve:

Speed
Cut accuracy
Tool life
Electrical stability
Remote monitoring
Safety compliance

Factories using older roll formers can achieve 30–50% performance improvement with targeted upgrades.

Why Documentation Matters More in 2025 Than Ever Before

Machine owners now face increasing demands from customers, auditors, and insurers for documented maintenance and electrical compliance. Proper reporting ensures:

Traceability
Accountability
Safety certification
Warranty protection
Regulatory compliance
Better resale value
Easier troubleshooting

Machine Matcher provides a complete documentation package for every service, making your maintenance department more efficient and your machine safer and more reliable.

Conclusion

Service reports, diagnosis reports, maintenance checklists, and upgrade recommendations are essential tools for maintaining modern roll forming machines. Machine Matcher offers a world-class reporting system designed to reduce downtime, eliminate guesswork, and give factories complete control over machine performance.

Clear reports. Smart decisions. Zero downtime.
Machine Matcher delivers it.

Machine Matcher now offers full electrical technician services for roll forming machines — including diagnostics, rewiring, testing, encoder calibration, PLC programming, electrical audits, and preventive maintenance.
We support all machine types and all global regions.
Contact us today for immediate technical assistance or to schedule a full electrical inspection at your factory.

Looking for the right roll forming machine or expert guidance on your next project? Machine Matcher is here to help. Our global team provides 24/7 technical support, expert advice, and guidance on machine selection, setup, and maintenance—ensuring your operations run smoothly from day one.

With team members based worldwide—including the UK, USA, Middle East, and beyond—we are equipped to assist buyers across the globe. Whether you’re sourcing a single machine or upgrading an entire production line, our experts are ready to provide tailored solutions and support every step of the way.

Get in touch now and let Machine Matcher help you find the perfect roll forming machine for your business.

United Kingdom (Main Office)
Phone: +44 20 335 56554

United States
Phone: +1 407 559 7948

Mobile / WhatsApp: +44 7816 972935

Email: [email protected]