In this article, we will consider 9 main techniques implemented in the work of Professional equipment maintenance. If we consider the process of any equipment from the point of view of preventing breakdowns, we can imagine it in the form of four main stages:
Warning stage. Certain work is done here to prevent equipment failure. They are implemented before a malfunction occurs, or when the first signs of a malfunction appear. Equipment at this stage is still working.
Stage of the reaction. A malfunction has already appeared. The equipment either stopped, or began to give out a low-quality product, or its speed slowed down. At this stage, the repair staff responds to the problem and begins to take action. There is still no direct elimination of the causes of malfunctions, only their search and preparation for elimination are carried out.
Stage of repair. The equipment is stopped and the immediate elimination of the causes of malfunctions, i.e. repairs.
Launch stage. The repair is completed, but the equipment continues to stand. This stage is often the longest, because It’s not enough just to turn on the equipment, it is necessary that it reaches the required quality and productivity. After start-up, the equipment should work at the same speed as before stopping, and also produce 100% quality product. Often the launch is complicated by all sorts of adjustments and settings inherent in a particular equipment and technology.
The following are nine professional service techniques aimed at reducing the duration of a given stage of failure prevention. The integrated application of most approaches is used in the planning of repairs: in the preparation of maintenance and repair work. Thus, each approach can be seamlessly integrated into an existing repair and maintenance system.
We list the tactics given here:
Substitution by nodes. The approach involves a significant reduction in time during equipment repair due to high-quality preliminary preparation. The principle of quick changeover is embodied here.
5S in the repair area. 5S is a system of rational organization of workplaces. You can learn more about 5S in the book “5S. Organization of jobs. ” Having rationally organized jobs can significantly reduce reaction time and repair time.
Analysis and warning. This is a constant analytical work, aimed primarily at preventing the appearance of a malfunction, as well as at accelerating the reaction when it occurs. Carrying out the analysis, we can, with varying degrees of certainty, predict the occurrence of a breakdown and can prepare for it.
Standard parameters. Standard parameters are necessary to eliminate the long adjustments, calibrations and adjustments that are often required when starting up equipment. The purpose of the approach is their complete exclusion and, as a result, time saving when starting up equipment.
Standardization of simple operations. Not one lean method is complete without standardization. In this approach, simple repair and commissioning operations are standardized: those that are most often performed. The approach saves the time of qualified personnel by directing them to diagnostics, training and prevention. Having a standard, simple operations can be performed even by unskilled personnel.
Work with current malfunctions. One of the most popular and effective areas of work. The essence of the approach is to timely prevent the occurrence of malfunctions, even at the stage of the appearance of the first signs.
Standard bypass routes. The approach is aimed at preventing breakdowns through periodic inspection of equipment, its diagnostics and maintenance by repair teams.
Signaling systems. Reducing the reaction time when a malfunction occurs or signs of a malfunction are often provided by various alarm systems. The goal is to quickly inform the repair personnel about the breakdown. Ideally, maintenance personnel should obtain information on the location and nature of the malfunction before the equipment stops.
Spare parts management. The approach involves the organization of accounting, storage, supply of the required number of spare parts. The purpose of the approach is to ensure the availability of a minimum number of spare parts, while eliminating downtime due to their shortage.
All of the above approaches are the most common areas of work when deploying Professional Services. Approaches are constantly being improved and replenished, adapting to the specifics of different industries.
Maintenance practices are evolving in sync with the challenges facing the industry. For example, at first, the production needed effective means of dealing with accidents. So, reactive maintenance became preventive. Later the focus shifted to asset health monitoring. This made…
The industry is gradually recovering from the effects of the pandemic, analyzing mistakes in risk management and looking for new mechanisms to counter the impending challenges. And there are enough of them: experts predict an increase in the deficit of…
According to McKinsey, equipment maintenance accounts for 10 to 25% of all operating costs. And these funds are not always spent rationally. Regardless of whether the enterprise implements maintenance and repair on its own or outsourcing, everyone encounters examples of…