Maintenance of industrial machines is a fundamental procedure to guarantee production quality. Bearing in mind that, by eliminating irregular stoppages, it is possible to reduce costs, in addition to increasing productivity and safety.
With this in mind, below we list arguments that prove the importance of this process, as well as tips on how to carry it out.
Good reading!
Why have an industrial machinery maintenance plan?
The maintenance of industrial machines concerns the process that analyzes the efficiency of equipment with the aim of generating greater productivity for the business.
In the textile industry, this procedure contributes to the company’s success, keeping it relevant in an increasingly competitive scenario. After all, there are already more than 24.6 thousand formal production units across the country, according to Abit.
Therefore, given market and consumer demands regarding product quality and personalization, maintaining high productivity is essential to satisfy demands.
Therefore, machinery in good condition is capable of continuously preserving work, eliminating losses due to downtime and costs caused by unexpected repairs.
In summary, a machine maintenance plan industrial systems is capable of conserving equipment and stabilizing the productivity of your industry. Regular reviews prevent problems, unplanned expenses and quality errors.
This is because it avoids risks generated by manufacturing failure, improper installation, inadequate lubrication and incorrect operation. In other words, by eliminating these errors, there will be no cracks, corrosion or exposure of parts to stress, as well as overheating and shocks. In short, it guarantees greater safety for everyone!
Maintenance prevents defects caused by incorrect operations. But it’s worth highlighting that failures are inevitable! In this case, the review process appears as a solution to minimize problems and prevent them.
Therefore, an efficient maintenance schedule not only guarantees the efficiency of operations, but also helps to understand the flow of processes and the logical sequence of activities.
How to create a machine maintenance plan?
The machine maintenance plan promotes checks, improvements and replacements of parts, for example, in a planned and structured manner.
Without pre-determination and constant analysis of the functionality of the machinery, there is no way to avoid waste, failures and a reduction in the useful life of the equipment.
However, to put together a good maintenance plan it is essential to follow some steps. They are:
- Mapeamento: map all equipment to collect data on location, operating conditions, daily operating time, expected useful life and procedures performed on each one;
- Manufacturer’s instructions: The manufacturer’s instructions must be followed exactly. After all, each piece of equipment must be strategically monitored;
- Maintenance Calendar: the maintenance calendar provides for periodic reviews, prioritizing machines and activities, to maintain the useful life of the equipment and reduce costs;
- Training: well-trained employees guarantee the success of the industrial machinery maintenance program;
- Technology: technological machinery enable connection with management software. This way you will not only have a data history and a broad view of the equipment, but you will also speed up operations and make more assertive decisions.
With all this information, it will be possible to develop a maintenance schedule that matches the size of your company and, consequently, production.
It is worth noting that in this machine maintenance plan it is necessary to choose those responsible for implementation, which could be managers, technicians or employees from the maintenance department, for example.
Additionally, it is important to set goals for cost and downtime during maintenance.
To put it into practice, download our free checklist and set up your Maintenance Planning and Control (PCM) now.
What are the main types of industrial maintenance?
The best maintenance of industrial machines will always be as planned! This is because improvisation can even avoid downtime, but it will affect the efficiency and quality of the final product.
However, there are 3 main models that can be used throughout the equipment review and monitoring process.
We highlight that the ideal is to use the three types of industrial maintenance to guarantee even more safety and agility in resolution.
Therefore, knowing the difference between them is essential to build a good machine maintenance plan and, thus, promote greater performance in your industry. Check it out!
Preventive maintenance
The first of these is preventive maintenance! This concerns the service that plans intervals and pre-determines them in order to reduce the probability of equipment failing.
With it you can achieve greater control and efficiency. This type of maintenance guarantees organization and production planning.
After all, periodic stops will be scheduled in order to allow the exchange of worn parts for new ones, thus ensuring the perfect functioning of the machine for a period.
According to an article on Maintenance of Industrial Machines and Equipment, the preventive method provides a certain work rhythm, promoting the necessary balance and a good progress of activities.
Therefore, preventive methods promote uniform and safe work, avoiding improvisation and unforeseen events.
Predictive maintenance
Predictive maintenance is also planned. Monitoring techniques are used here to predict when the next failure will occur. The aim is to determine the exact time for intervention and the useful life of the equipment components.
Therefore, mechanical vibrations, oil and lubricants are analyzed, in addition to thermography and ultrasound testing. In other words, it involves evaluating the condition of the machine to use it in the best possible way during its lifetime.
According to the article mentioned above, the main objectives of this maintenance are:
- Determine, in advance, the need for maintenance services on a specific part;
- Eliminate unnecessary disassembly for inspection;
- Increase machine availability time;
- Reduce unplanned emergency work;
- Prevent damage from increasing;
- Enjoy the full useful life of components and the machine;
- Increase the degree of confidence in the performance of an equipment or production line;
- Pre-determine manufacturing interruptions to take care of equipment that needs maintenance.
Therefore, it will indicate the real conditions of the machines, stating their possibility of functioning. All based on data that indicates wear or degradation processes.
Corrective maintenance
The corrective is the only one that is not planned. It works to immediately correct the problem generated by the machine.
According to ABNT, cited in the article Industrial Maintenance, it is defined as “maintenance carried out after the occurrence of a breakdown, intended to put an item in a position to perform the required function”.
Therefore, this process is based on unpredictability and improvisation. Therefore, there are no methods, techniques or formulas that define it. Here, the objective is only to resolve the emergency with conduct consistent with the problem caused.
Therefore, it is necessary to have maintenance teams available to respond to any readiness request. However, industries do not always have enough professionals for this work.
However, even industries that use planned maintenance more must have a specialized technical team to carry out emergency maintenance.
Next step
The next step is investment in textile machinery technological, efficient and modern. As we saw previously, technology is part of good maintenance planning for industrial machines.
In this way, the equipment will be able to generate data capable of improving monitoring and, therefore, preventing and predicting repair times.
So talk to our consultant to learn about Delta’s solutions and start investing in agility and quality.
