The culture of maintenance, based on a positive and caring attitude towards technology - it is one of the most important assets of the enterprise. Culture determines behavior. The behavior affects the quality of work. The quality of work is at the core of the enterprise reliability and cost of providing this reliability.
Improving safety and security should be the main goal for each enterprise. Reliability of equipment - is the science of behavior that permeates all levels of the company, from management to production staff.
Maintenance requires strict planning and management of the work schedule. Shotgun approach to the planning schedule maintenance work is destructive and is associated with high costs of the enterprise. In addition to good planning, we need more, and early warning system. It is impossible to schedule the removal of the fault, if we are not able to anticipate that it will need.
We can diagnose the fault of the machine, including its six senses (for example: we can hear unusual noise or smell, or see a puddle of oil on the floor). But in this case we find already formed a breakdown of the machine unit, which will lead to equipment damage, if we do not address it immediately. We can not prevent a downtime of product line or enterprise, and prevent financial losses.
To detect equipment faults at an earlier stage, when there is the beginning of failure, it is necessary to conduct a diagnostic monitoring equipment units. Diagnostic monitoring includes both proactive and predictive maintenance. Proactive service aims to find and eliminate the root causes of failure long before it will need repairs. Predictive service complements the proactive service. It is aimed at finding signs of malfunctions - the sooner the better. High service culture is a culture of proactive maintenance.
Proper maintenance program and repair of equipment ensures a reduction of maintenance costs by up to 46% and helps to keep all the important functions of the enterprise in a secure, safe and efficient state. .
The mission of our team is to help our customers make their business a reliable, safe and highly effective due to the formation of the optimal maintenance and repair program.
Our specialists have a wealth of knowledge and experience in the field of equipment reliability. We are ready to help you create the right culture of maintenance and operation of the equipment and reduce financial losses.
We offer you:
Building a proactive maintenance system:
Analysis and validation of the existing maintenance program and repair of equipment. We will help you make an assessment of the current performance of existing equipment maintenance program and define the goals for building a proactive system.
Building AssetHealth system. AssetHealth program (Management assets state) will help you to understand the current technical health of your equipment, structure equipment in accordance with the process and the influence on it, build a system of rapid determination of the deterioration of your assets by defining critical parameters at each stage of the process, set up a report system on equipment status, define a strategy for the maintenance of each individual piece of equipment and systems in general. AssetHealth program will help you to plan effectively maintenance of equipment and the work of maintenance and repair of the equipment service.
Construction of equipment criticality system. Having built up a system for evaluating the criticality of the equipment at your business, you can easily foresee any risks related to the security of our business. Analysis of the criticality of the equipment is based on an assessment of the impact of every single machine on our results of operations, and this: a) impact on security; b) impact on the environment; c) impact on product quality; г g) impact on suppliers; e) impact on the process.
Identifying the degree of criticality of each unit process, we define risk management system associated with its work, identifying and implementing actions to reduce the impact of risks on business.
Drawing up a maintenance program and repair of equipment. We will help you to create the optimal maintenance and repair program for each piece of equipment, or to optimize existing, determine the mode of operation of equipment and its control system malfunctions (MTBF, scheduled preventive maintenance).
Construction of RCM and FMEA. RCM (ReliabilityCenteredMaintenance- maintenance, reliability-oriented) is a methodology, which allows to determine the necessary steps to ensure that each production system and its components fulfill their function within the production process. Compliance with the requirements of reliability and safety of the technological process and equipment, while ensuring the maximum level of efficiency due to the formation of the optimal maintenance and repair program.
Planned precautionary maintenance (PPM) is still considered the most advanced and effective method for industrial organizations. RCM approach is an optimal combination of various methods of service (repair) on the fact of damage, according to the calendar, on condition, preventive. These different strategies are combined into a set, designed to maximize reliability while minimizing the cost of the equipment life cycle (TCO).
FMEA(Failure Modes and Effects Analysis – Analysis of failures and their consequences)em> is a methodology, which aims to improve the process based on the analysis of potential equipment failures with a quantitative analysis of the effects and causes of failure. The study of the causes and mechanisms of occurrence of failures, preventing failure or minimizing the negative effects on them. As a consequence, a reduction of elimination of consequences of failure costs, improving end product quality and reliability process.
FMEA principle applies to every system, subsystem, and objects defined within the system boundaries. several types of failures can be defined for each function. In FMEA approach, each system function is analyzed and allocated the dominant failure modes. Then the consequences of failure are considered (performance object loss, failure of the system, and so on. n.).
Optimization of operating maintenance and repair process, the construction of workflow diagrams. Having built up the correct process of planning the maintenance and repair at all stages and developing operational workflow diagram, we will help you to structure the work of maintenance and repair services, its interaction with all units (participants of the process), as well as reduce the time loss on service and efficiency maintenance and repair services.
Making evaluation standards of the technical condition of the equipment . The deterioration of the technical condition of the equipment is largely reflected in the quality of the end product and production. Technology staff in most cases sees the development of equipment failure (minor change in the sound when using the equipment, oil stains, etc.), but the reaction to the elimination of breakage is not always on time. Often begin to repair when released a large number of defects or equipment is completely out of order. Introducing the system in each area of process equipment technical state standards, you can define the boundaries of failure and react to it to complete equipment failure and eliminate the issue of defective products.
Building maintenance and repair proactive system.
Creating a rotation system of spare parts. Purchase of spare parts is an important item in the budget for the maintenance and repair service. Reducing the cost of replacement products without compromising the reliability of the process - a priority task of chief engineer. The purpose of spare parts rotation system is to minimize costs for the purchase of replacement products and « transparency » of the rotation.
Optimizing the value of the technical warehouse based on ABC analysis of spare parts. ABCN analysis involves categorizing replacement products, aimed at identifying replacement products belonging to certain categories of criticality, amortization and accessories to the process or equipment. The purpose of the analysis ABCN - minimize the number of parts in maintenance and repair stock, and the cost of storage as a whole, without reducing the level of equipment reliability, optimize spare product procurement process and reduce costs for spare products.
The condition of equipment monitoring:
Carrying out complex diagnostic monitoring the technical condition of equipment and drawing up a specific list of measures to maintain the original equipment functions. The complex diagnostic monitoring includes: vibration diagnostics, ultrasound diagnostics, oil analysis, thermography and data analysis;
Conducting periodic diagnostic testing of equipment and systems. 1. The customer selects frequency : once a month, quarter, six months, one year; 2. We help the customer to determine the optimal frequency of the diagnosis based on the criticality of systems / equipment;
Carrying a single diagnostic check to identify faulty equipment and preparation adjustments maintenance plan. Perform maintenance on the results of the diagnosis; Conducting ongoing monitoring of the status and preparation equipment maintenanceplans, database maintenance plans, equipment status (weekly monitoring);
Carrying out oil analysis (moisture, impurities).
Identifying the root cause of the failure of equipment and preparation of corrective and preventive action plans;
Preparation of diagnostic monitoring program for each unit / type of equipment;
Drawing up standards of reliable operation of the equipment (ranges trouble-free operation parameters) applicable both to assess the current condition of the equipment, and determining the level of reliability of the equipment buying, installing and commissioning.
Implementation of thermographic inspection equipment, electrical installations, buildings, pipelines, both one-time and permanent with recommendations for repair and maintenance of database changes in the state of equipment and systems.
Conducting complex maintenance of equipment on the basis of diagnostic testing.
Laser alignment equipment.
Carrying out maintenance of the equipment complex for the current program of maintenance and repair.
Work on installation of technological equipment.
Manufacturing spare parts (shafts, gears, sprockets, bushings, guides, rollers, etc.) of any material.
The equipment condition monitoring system helps reduce maintenance and repair costs and increase the reliability of the company as a whole. A system of management and of the planning, and stocks of spare parts are optimized with the use of diagnostic control. On the other hand, the level of implementation of monitoring system has a high cost. This is due to the high cost of diagnostic equipment and training of maintenance and repair service personnel, loss of time, and sometimes the creation of a secure card. Implementation of monitoring system certainly pays invested funds for its creation, but the payback period can be varied, depending on the conditions of its implementation (technological level and enterprise development, staff qualifications, equipment park).
Examples of identified defects:
1. Defect inner ring
2. The defect of the rolling elements
3. Defect bearing grease
Starting to work with us, you will reduce the costs of implementation monitoring system, or a system of maintenance and repair of the equipment. You do not have to buy expensive equipment and invest in staff training. We have all the necessary tools for diagnostic monitoring and maintenance (Pruftechnik, ProvibTech, FLIR, etc.). Our experts have a 2 and 3 level of certification in accordance with ISO 18436-2. We will train your staff the basics of diagnosis.
We offer you to find together the most optimal way for you to work with us, whether it be a one-time service or continuous service.
Transformations in the culture of maintenance – not an easy task. Start the transformation program with us. We will help you to achieve the highest level of service and reliability of your business.