„Maintenance requires a high degree of discipline and flexibility.
If important machinery and equipment fail in production, it can become a hectic one. For example, the bands can not stand still at our German car parks. „
1. REQUIREMENT OF MAINTENANCE SERVICES 1.1 Short-term work – Suppression – Unplanned repairs!
The work to be carried out at short notice, interference suppression and unscheduled repairs are handled by the maintenance department. The order is made by telephone or by the direct response of an employee.
The work is to be recorded in writing and is prepared by the department’s supervisor (form work plan requirement) and stored in a computerized form (for the time being, by means of an excel table and later by the BDE).
The requirement clearly shows which work is requested by the maintenance department. Start of the fault, type of fault, range where the fault occurs. Approval of the machine by the responsible maintenance person – acceptance of the work by the supervisor of the production. The maintenance has only a very limited staff, therefore, before each commissioning should be carefully decided whether the works really
Must be completed immediately. The core business is the maintenance of production.
Creating a Priority List Production Machines – Infrastructure – Operations Engineering.
At simultaneous presentation of several tasks, the maintenance not all
Immediately, the department heads decide on the order of the work.
1.2 Maintenance & Inspections – Scheduled Maintenance!
Maintenance, inspections and all planned maintenance work are carried out by the maintenance team.
Repairs of which the scope is known and where the schedule can be planned are handled and carried out by the maintenance team. Orders are issued by the manufacturing, planning, control and maintenance department. Manufacturers and service providers with service or maintenance contracts are part of the maintenance team Together with a maintenance schedule (week-month-year), in which the maintenance intervals, inspections and deadlines are recorded.
2 MAINTENANCE – PERFORMANCE 2.1 Suppression!
An interference suppression is used for the rapid restoration/restart of production plants and can not be deferred.
As long as the quality requirements can be produced accordingly, one
Machine as functioning. Disorders which present an immediate danger to man and the environment or Further consequential damage can be immediately followed immediately
.Destructions are carried out by the personnel of the production or by the maintenance staff. If the interference is not carried out by the employees of the production, the maintenance will be commissioned -telephone or the employee’s remarks. -Destructions are made by the responsible supervisor of the production in Form of fault messages. The message will appear immediately after the fault occurs
And contains the start time and fault image of the fault. The maintenance engineer reports the completion of the activities to the customer and documents the work and the end time of the interference suppression (forms are created and available). The messages are completed by the maintenance manager and the supervisor of the production.
2.2 UNPLANTED MAINTENANCE
Unplanned maintenance is done in response to an unpredictable
Damage to a machine. This includes the error search at sporadic
Occurring faults which repeatedly lead to the failure of the system.
Repairs are carried out and processed by the maintenance department.
The employees of the maintenance team support maintenance.
In the case of a lack of personnel or if special tools and abilities are required, foreign service providers may be consulted. The commissioning is carried out by the maintenance department and the production line.
Repairs are documented and documented as the interference by the customer. The completion of a repair is reported back to the departments and the work is carried out by the department managers. If further work results from a repair, these must be documented by the maintenance department (replacement of a component for overhauling – replacement of spare parts, etc.).
2.3 PLANABLE MAINTENANCE
Activities whose scope is known and where the schedule can be planned are handled and carried out by the maintenance team. The request is made by the supervisors of the production and the maintenance.
The work is documented and documented (serves the further damage analysis).
After completion of the repair, the machine is transferred to the machine and removed by the department manager.
Foreign service providers, manufacturers and suppliers who are involved in a service contract or maintenance contract are also included in the maintenance team.
The employee documents the work and the means used, the time required and all established facts.
If no deviations from the work plan are determined, the order is sent
Marked as completed by the employee and documented in the machine book with a signature.
2.4 MAINTENANCE AND INSPECTIONS
Maintenance and inspection work is carried out by the maintenance team of the maintenance, supported by autonomous maintenance of the production.
Maintenance and inspections are described in routine catalogs and are not requested or commissioned. The maintenance schedules automatically determine the dates and maintenance / inspection orders.
Maintenance plans, checklists and machine books for recording the activities are managed and checked by the maintenance department.
2.5 AUTONOMIC MAINTENANCE MANUFACTURING
The employees of the production can carry out simple maintenance and maintenance work (eg lubrication of the machine guides – reading of setpoints and oil level control) using work plans, checklists and routine catalogs. The cleaning of the machines of castings and other waste is carried out on the part of the production (work safety). The work to be carried out is described in detail using workflows with photo documentation, the work plans are displayed on the machine, the work is documented by the employee’s signature in the checklist in the machine book. The maintenance team supports the production staff in their tasks and becomes knowledge through training To strengthen the importance of this work.
2.6 USE MACHINE STILL / RUN TIME
When retrofitting the system to a new product / tool, the maintenance team or the maintenance team must be informed immediately. During the planned set-up work, some of the maintenance and inspections can be carried out on the machines (eg lubrication work, checking the set points etc).
Maintenance can take advantage of the time to look more closely at the machines and plan further measures. Each machine stop must be used to carry out preventive maintenance.
In order to relieve the maintenance of some tasks, service and works contracts with manufacturers and suppliers are concluded for certain areas.
Supervision of third-party service providers is ensured by the maintenance team.
Planning of the work and deadlines are defined by the maintenance department and the production planning – control department.
The use of service providers and their work is precisely documented and controlled by the maintenance department according to type and scope. The work of third-party service providers is subject to warranty and warranty claims are additionally secured.
Thus, parts of the building technology, the infrastructure, and e.g. The banding equipment can be delegated into the hands of service providers, which allows the maintenance business technology a concentration on their core business.