Maintenance organization Example of production
Organization includes the „Designing systems for achieving goals and completing tasks
Maintenance requires a high degree of discipline and flexibility.
When critical machinery and equipment fail in production, it can be hectic and stressfull. The bands in the automobilproduktion can almost never stand still.
Good organization and standardized processes facilitate it here maintenance and production defects and failure to respond and take appropriate action.
Through the consistent maintenance documentation is to be found in the location weaknesses and permanently eliminate.
Standardized error messages and error reduce provide „predictable“ faults and run on an analysis.
Errors and faults can have various causes
There are many different options for an efficient maintenance management and we would like to introduce a system.
Introduction of a maintenance management for production systems by means of MDE (Machine Data Acquisition) BDE (Operating Data Acquisition) for cataloging disorders:
In many manufacturing operations any automatic systems for the detection of faults and errors exist. Often be made in a fault list, automatically a subjective component is taken up in the data manually records.
It is therefore imperative that the output of the machine / equipment fault messages, 1st match the disorder and describe them so that the operator knows what it is; 2. describe the precise location and nature of the fault 3.On standardized texts based and is continuously recorded and archived.
The cataloging of errors and faults varies with time and the equipment and the context of the application area change as well as the measured data are cataloged on the basis of interference. Therefore, the cataloging needs to be updated constantly and the changed conditions to be adjusted. It cannot be construed as a one-time process but must be constantly maintained.
Based on the cataloging of faults / errors, a process is set up in the maintenance, which leads into 7 steps to a successive optimization of the plant and machinery and preserving the values of machinery / equipment.
First you should find out what the others all know, and then pick up where they left off. Thomas Alva Edison
Identify, document and catalog
Phase 1 Standards for error and faults
All errors and faults must be recorded accurately and consistently documented.
-the Nature of the error / fault
Place of birth and equipment where the error occurs
-Time Of the appearance and duration of the outage
-Time The restoration of the function
Expense of personnel, tools, materials
The detection of errors should be made by MDE .It can also be manually entered in bug reports, but it requires to maintain a standardized description of the fault to subjective impressions as low as possible.
The error messages of the MDE must match the displayed fault and give the employee precise information on the cause of the failure.
A standardized description of the fault can be done as CIP project.
Phase 2.- determine the exact impact of errors / faults
For the cataloging of errors / faults is to determine the effects of enormous importance.
-error time X = clock loss severity
– rework due to manufacturing defects
Together cause -Analyze which causes an error
In consideration not only the equipment on which the error occurs alone, but the whole context of a system shall be fitted. So quality failures can lead to increased rework.
Phase 3.- determine the exact cause of bugs and glitches
The detailed analysis of the causes of an error / fault must be performed by qualified service personnel. The main task is to find out in detail what caused the error / faults.
Disruptions due to component geometry – Design related problems
Disorders due to mechanical problems
Disorders by electrical problems
Disorders due to program errors
Disorder caused by incorrect operation
Disorder caused by external factors (cooling water outside temperatures)
The analysis of errors and faults requires a skilled approach and a very positive attitude of the staff. Here, a halt more than just a step backwards !!!
Phase 4.- establishment of a Top Ten of the 10 most important error
Set – disturbance frequency clock x = loss severity
Create -Top Ten list of errors
-There Are the 10 most common errors are fixed and the disturbances are analyzed together exactly in what context are.
During the startup phase of a machine / plant a detection system as MDE identified a variety of errors (often a hundred or more) per layer. To utilize the resources of maintenance as efficiently as possible, it is necessary before further steps make a selection of the most significant errors / faults.
These are the disorders that show the negative effects and have the greatest severity, the product of errors and clock loss.
After analyzing the 10 most significant disturbances are coordinated by the maintenance management work.
Phase 5.- Define strategies for permanent error reduce
Once the causes of the disturbances are analyzed and cataloged, a common strategy be developed for sustainable elimination of faults.
The maintenance is coordinating the necessary measures and tasks.
On the basis of the costs associated with a load runtime loss and the number of lost load at runtime by the respective disorder was determined in Phase 2, it is possible to determine the ROI of expenses that caused the fault clearance. Thus, one can assess whether your actions represented in economic terms.
Examples of measures:
Alteration of the system programming
-Change Component geometry
-Change Of tools
Alteration of mechanical components
Alteration of electrical components
-Training And training measures
It should always be borne in mind that may arise from the implementation of the remedies new additional interference and thus load term losses.
Phase 6.- Implement measures to reduce errors
-By Accurate analyzes, standardized error catalogs and on the basis of the technical and economic assessment of the defined measures are implemented.
Experienced maintenance and system optimizer accompany the process and document the implementation.
Phase 7.- Verify success of the implemented measures
-The Troubleshooting measures are to be verified on the basis of data from the MDE whether they achieve the desired success. The disturbances should be consistently disappear from the top ten list.
Based on the data analyzed here and pay the maintenance can develop a cost model that differs from the conventional positive.
Many manufacturing companies expect the maintenance costs evenly over all production areas from a simple determination and allocation of costs to have.
While this provides a simple representation but is not very transparent and ensures high overhead costs in the company. Through constant development and maintenance costs are a perfectly respectable size, and must therefore be specifically designed and economically reasonable.
From the sequence out many companies have begun to achieve a reduction of maintenance costs by reducing appropriations.
This has often led to sub-optimization and machine / equipment have suffered in their function.
The model presented here, the service can improvements to machinery / equipment cost requirements shown. The costs resulting from the actual clock losses, which can be saved by the improvements plus the cost per clock cycle.
The positive costs can then be made available to the maintenance costs compared to.
Thus it can be calculated if the maintenance work has impacted positively or negatively.
Thus, the aim is not only to reduce the maintenance cost but to maximize the value of an investment and productivity !!!