The life cycle of equipment and machinery generally passes through five stages: operation \u2192 failure \u2192 repair \u2192 operation \u2192 removal\/replacement. Consequently, proper equipment maintenance will:<\/p>\n
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- Prolong the lifespan of the machinery and equipment<\/li>\n
- Enhance the performance of the machines<\/li>\n
- Reduce downtime due to malfunctions and repairs<\/li>\n
- Ensure worker and production safety<\/li>\n
- Prevent major mistakes from affecting the entire production line<\/li>\n
- Assist in reducing production costs.<\/li>\n<\/ul>\n
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<\/a><\/p>\nWhen to perform maintenance?<\/strong><\/h2>\n
To ensure efficient operation of equipment, businesses need to be mindful of the appropriate timing for machinery maintenance. Each type of equipment has a different maintenance schedule, which depends on factors such as the working environment (climate, weather), the design of the equipment, and the operating method and hours of the plant.<\/p>\n
For instance, the maintenance schedule for a factory operating 24\/7 will be shorter than that of a factory with intermittent operations. Outdoor equipment should be regularly inspected, lubricated, and serviced to maintain optimal performance.<\/p>\n
Typically, newly installed machines or robot systems will undergo maintenance three times in quick succession (every 3 months), until the system is running smoothly. Afterwards, the maintenance intervals will be extended (to every 12 months or more).<\/p>\n
Industrial equipment maintenance methods and procedures<\/strong><\/h2>\n
Basically, the maintenance of machines is based on their life cycle: operation \u2192 failure \u2192 maintenance, repair \u2192 operation \u2192 removal\/replacement. Based on this process, we can classify the maintenance methods as follows:<\/p>\n
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\n Method<\/strong><\/td>\n Explanation<\/strong><\/td>\n Advantages<\/strong><\/td>\n Disadvantages<\/strong><\/td>\n Application<\/strong><\/td>\n<\/tr>\n \n Restorative maintenance<\/em><\/strong><\/td>\n Performed only when the machine has started to fail and is essential to repair and restore it.<\/td>\n Initial cost savings<\/td>\n -Interrupts the production process<\/p>\n -Does not ensure labor and production safety<\/p>\n
-High repair costs when machinery malfunctions. May even require replacing the machine due to irreparable errors.<\/td>\n
Small production facilities, factories without a continuous line<\/td>\n<\/tr>\n \n Preventive\/Predictive maintenance<\/em><\/strong><\/td>\n Periodic maintenance based on the reliability of the equipment’s components (the useful life of the equipment’s parts)<\/td>\n Extends the life of the machinery and minimizes potential damage ahead of time.<\/td>\n Periodic maintenance expenses<\/td>\n Small production facilities, factories with a continuous line of operation<\/td>\n<\/tr>\n \n Opportunity maintenance<\/em><\/strong><\/td>\n Maintenance performed when the factory is not in production or during off-shift times.<\/td>\n Does not affect the production line during repair<\/td>\n Requires synchronization of production and maintenance time<\/td>\n Small production facilities, factories with intermittent operations<\/td>\n<\/tr>\n \n Condition-based maintenance<\/em><\/strong><\/td>\n Maintenance based on data obtained from the sensor system, allowing engineers to determine the condition of the machines and perform necessary maintenance before equipment damage occurs.<\/td>\n Saves on periodic maintenance costs<\/td>\n <\/td>\n Small production facilities, factories with continuous or intermittent production lines<\/td>\n<\/tr>\n \n Predictive maintenance<\/em><\/strong><\/p>\n <\/td>\n
Maintenance based on data analysis to predict the condition of the equipment in the future and plan operations accordingly.<\/td>\n Maximizes equipment life and optimizes production operations.<\/td>\n Requires highly qualified maintenance personnel with the ability to predict potential equipment failures.<\/td>\n Factories with a continuous line of operation<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n 4 ways to maintain industrial equipment<\/strong><\/h2>\n
Factories often adjust their maintenance method based on the type of equipment to save time and costs.<\/p>\n
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- Main equipment maintenance (devices primarily responsible for creating quality, safety-assured products and subject to preventive or condition-based maintenance).<\/li>\n
- Important equipment maintenance (devices that affect the line, but only for backup purposes, maintenance should only be performed based on condition and repair plan when signs of damage occur)<\/li>\n
- Auxiliary equipment maintenance (not essential equipment with little impact on the production process, so restorative maintenance can be applied)<\/li>\n
- Whole plant maintenance<\/li>\n<\/ul>\n
OEE Solution<\/strong><\/h2>\n
The Overall Equipment Efficiency (OEE<\/a>) solution measures the productivity and operational efficiency of equipment. OEE helps businesses determine the percentage of efficient production time, evaluate problems during use and maintenance.<\/p>\n
<\/a><\/p>\nOEE brings many benefits to businesses, including: <\/em><\/strong><\/p>\n
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