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M&DC-TPM-برنامج الصيانة الإنتاجية الشاملة-فوائد تطبيق الصيانة الانتاجية الشاملة

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ثالثا-الخطوات الصحيحة لتطبيق الصيانة :

1. تحديد الآلات والأجهزة المراد صيانتها .

2. تحديد جميع عمليات الصيانة من واقع تعليمات المورد أو المصّنع الموجودة في كتالوجات الصيانة .

3. عمل الجداول الخاصة بعمليات الصيانة حسب نوع الصيانة المطلوبة .

4. استحداث خطة الصيانة.

5. اختيار وتدريب العمالة الفنية .

6. توفير قطع الغيار.

7. توفير العدد والأدوات .

8. استحداث نظام تسجيل المعلومات : نظام أمر العمل .

9. تنظيم أعمال الصيانة وتوزيع المسؤوليات .

10. مراقبة تنفيذ خطة الصيانة .

أولاً - المقدمة : وتشمل : تعريف الصيانة وأهميتها .

نظرا للتكلفة الباهظة الرأسمالية لمكونات المشاريع التي تنفق حتى إكمال المشروع والتي تبلغ في معظم الأحيان ملايين الريالات . فمن البديهي أن تتم المحافظة على تلك المكونات الباهظة القيمة من جميع المؤثرات التي تؤدي إلى تلفها أو إنقاص عمرها الافتراضي . وتتم المحافظة على هذه المكونات بإجراء الصيانة الصحيحة المخططة والمدروسة لجميع مكونات المنشأة بدون استثناء . والمشكلة تكمن في بعض الأحيان أن إدارة المنشأة تتجاهل دور الصيانة الصحيحة بجميع أنواعها المختلفة بدافع تقليص المصروفات لزيادة الربح .

وتلجأ في العادة إلى اعتماد نظام الصيانة التقليدية القديمة( الإسعافية ) وهي صيانة الإصلاح وقت حدوث العطل . وعندها تدفع أضعاف ما تم توفيره من أموال نتيجة تجاهل تطبيق الصيانة الصحيحة بجميع أنواعها. وقد تنبهت جميع الدول الصناعية لذلك وتخلت عن الاعتماد على نظام الصيانة الإسعافية منذ عهد الخمسينات وطورت برامج الصيانة لديها ليشمل جميع أنواع الصيانة الوقائية والتوقعية والرقابية والإنتاجية وغيرها من الأنواع المختلفة التي تضمن الحفاظ على مكونات المنشأة وزيادة عمرها الافتراضي وجودة وزيادة الإنتاج .

وفي هذا البحث سوف نلقي الضوء عن الطريقة الصحيحة لتطبيق الصيانة بجميع أنواعها على مكونات المنشأة المختلفة .

هي: عبارة عن مجموعة الإجراءات وسلسلة العمليات المستمرة التي يجب القيام بها بهدف وضع الآلة في وضع الاستعداد التام للعمل .

والصيانة عملية حتى في حالة وقوف العملية الإنتاجية للآ لة حيث تتعرض أجزاء الآلات والمعدات وأجهزة الإنتاج للأعطال مثل التآكل والتلف والصدأ خلال فترة عمرها التشغيلي .

ويبرز الدور المهم لعمليات الصيانة في تحقيق الأهداف الآتية :

ا - المحافظة الدائمة على الحالة الجيدة للآلة والمعدات وضمان حسن الأداء وبالتالي جودة الإنتاج

ب - الإقلال من حدوث الأعطال وما تسببه من خسارة اقتصادية لعملية الإنتاج نتيجة لتوقف الإنتاج وتكاليف إعادة التشغيل .

ج - زيادة العمر الافتراضي للآلات وبالتالي الحصول على عائد اقتصادي أكثر جدوى .

د - تحقيق ظروف تشغيل مستقرة وبالتالي زيادة شروط ومناخ السلامة الصناعية لمواقع العمل .

وغيرها من الأهداف حسب مواقع العمل المختلفة .

ثانياً- معرفة أنواع الصيانة .

تنقسم أعمال الصيانة حسب نوع العمل إلى الآتي :

هي مجموعة الفحوصات والخدمات التي تتم بصفة دورية وحسب خطة زمنية موضوعة ( تحدد من قبل مصنعي الآلة أو من قبل الفنيين ذو الخبرة القائمين بالصيانة ) لمعالجة القصور إن وجد قبل وقوع العطل أو التوقف عن العمل .

وتتم عمليات الصيانة الوقائية يوميا وأسبوعيا وشهريا حيث الفحص الدوري الظاهري لأجزاء ووحدات الآلة وأجراء عمليات التنظيف والتشحيم والتزيت وتغير بعض الأجزاء البسيطة إذا لزم ذلك .

هي مجموعة العمليات التي تتم لإصلاح الآلات حسب خطة زمنية موضوعة ( تحدد من قبل مصنعي الآلة أو من قبل الفنيين ذو الخبرة القائمين بالصيانة ) ويتم فيها :

- تغير الأجزاء التالفة أو الأجزاء التي انتهى عمرها الافتراضي .

- إجراء عمليات الإصلاح على بعض الأجزاء بهدف إعادة استعمالها مرة أخرى مثل ( إصلاح الجزء المتآكل أو المتشقق جزئيا باللحام .)

- إجراء عمليات الضبط والمعايرة لبعض أجزاء الآلة التي تحتاج إلى ذلك .

هي مجموعة العمليات التي تتم لإصلاح الآلات نتيجة لحدوث تلف مفاجئ يؤدي إلى وقوف الآلة الغير مخطط لها . وعادة ما يكون سبب هذا العطل من عدم إتباع تعليمات المصّنع ( التشغيل الخاطئ) أو عدم تطبيق الصيانة الوقائية الصحيحة .

قبل البدء في سرد خطوات تطبيق الصيانة لابد أن نذكر أنه من واجبات الإدارة المسئولة عن المنشأة اختيار الشخص المسئول عن الصيانة أولا ، وهو الشخص الذي سوف يحمل على عاتقه عبء تنفيذ هذه الخطوات ويتم دعمه بالكامل من قبل الإدارة لتذليل كل الصعوبات التي قد تعترض تنفيذ خطوات تطبيق الصيانة .

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ما هو مفهوم الصيانة و الغرض من عمليات الصيانة ؟ - تخصصات بيت.كوم

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ثالثا-الخطوات الصحيحة لتطبيق الصيانة : تحديد الآلات والأجهزة المراد صيانتها . تحديد جميع عمليات الصيانة من واقع تعليمات المورد أو المصّنع الموجودة في كتالوجات الصيانة . عمل الجداول الخاصة بعمليات الصيانة حسب نوع الصيانة المطلوبة . استحداث خطة الصيانة. اختيار وتدريب العمالة الفنية . توفير قطع الغيار. توفير العدد والأدوات .

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What is Preventive Maintenance? Types, Examples & Solutions [2019]

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UpKeep is a modern, intuitive, and mobile first CMMS that is proven to streamline the work order process. Schedule preventative maintenance and tasks with ease. Try UpKeep free today.

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We've talked about preventative maintenance before on our blog, and where it stands on the continuum relative to other types of maintenance. But that's not the end of the story; there are different approaches to preventative maintenance itself, all of which are used to ensure your equipment is operating correctly and potential problems are identified.

Knowing which method of preventative maintenance to use isn't always a straightforward decision. Depending on the complexity and value of your equipment and the possibility of compliance requirements, you might use more than one approach. Below are the five common types of preventative maintenance in use at commercial facilities today, along with some preventative maintenance examples.

1. Time-based Maintenance (TBM)

When you change an air filter once every six months, you're practicing time-based maintenance. Time-based maintenance activities might involve anything from inspecting and cleaning to servicing and part replacements. The frequency of TBM is usually predetermined according to the equipment supplier's recommendations and/or past performance of the machine.

TBM has some advantages and disadvantages as a maintenance strategy. It uses less manpower than some other maintenance strategies. But even though you're following the set schedule, in some cases you may be changing or servicing something before it actually needs to be done. For example, a manufacturer may recommend replacing a fan filter every three months, but if that filter is located in an area of the building where it isn't used often, you could go longer without replacing it. That makes the cost of TBM higher than it should be.

Another maintenance strategy, condition-based monitoring (discussed below) can help prevent over-maintenance, and is seen as generally more valuable and economical than TBM.

2. Failure-finding Maintenance

Failure-finding maintenance is conducted to ensure that something-often a protective device of some sort-still works. Protective devices are those designed to call attention to a problem, shutdown a process to prevent further problems, and guard against accidents. Activating an alarm occasionally would be considered failure finding maintenance.

While other types of preventative maintenance involve regularly changing or replacing parts, or noticing an apparent condition that might indicate imminent failure, failure-finding maintenance applies to hidden failures that can be uncovered only by actually checking if something still works. By some estimates, up to 40 percent of failures in industrial settings fall into the hidden category; and up to 80 percent of those require failure-finding to be rooted out. An example of this type of preventative maintenance: A diesel generator might have a protective device that should shut down the generator in the event of elevated cooling water temperature; the functionality of that device will not be discovered without simulating the appropriate conditions and checking if the device gives the right response.

Unfortunately, failure-finding maintenance is usually given low priority by maintenance professionals, but it is critical to maintaining a safe environment -and sometimes preventing the major disasters that happen as a result of multiple failures.

Failure-finding maintenance is usually given low priority by maintenance professionals, but it is critical to maintaining a safe environment. Click To Tweet

3. Risk-based Maintenance

Risk-based maintenance is a strategy that aims to decrease mechanical failures by evaluating the levels of risk associated with your equipment, and then prioritizing your maintenance activities accordingly. The theory behind risk-based maintenance is essentially Pareto's Law, which, when applied to maintenance, holds that 80 percent of failures are attributable to just 20 percent of your equipment; therefore it makes sense to focus your efforts on those areas.

Both the probability of a failure and the consequences of a failure are considered in support of this approach. Based on the results of your evaluation, you can make better decisions about what to inspect, and when. Many times facility managers do this unconsciously as part of their routines, but it's more effective at delivering results when a methodology is used to help make decisions. When done right, risk-based maintenance can optimize both asset performance and your financial resources as well.

4. Condition-based Monitoring (CBM)

Condition-based monitoring involves monitoring the condition of a piece of operating equipment or machinery to determine what type of maintenance needs to be done and when. Signs of declining performance or imminent failure would indicate maintenance needs to be done to restore the machine to its previous level of performance and reliability. This approach is designed to avoid a breakdown by fixing problems before they occur, which means it is a type of predictive maintenance (number 5 below).
CBM is a more effective preventative maintenance strategy than time-based, because it is a proactive measure intended to specifically identify changes in machine performance and head off issues.
Examples of what elements could be monitored to diagnose problems are:

Visual-This is the most basic form of condition monitoring and may uncover things like cracks or corrosion.

Vibrations-Changes in the vibrations produced by compressors, pumps, motors and other types of equipment can help spot performance problems.

Wear debris (tribology)-Analyzing interacting machine surfaces for wear and fractures may serve as an early warning of equipment failure.

Temperature (thermography)-Corroded electrical connections, faulty machinery, and damaged machine components can all change the temperature distribution of running equipment.

Sound-The sound of a running machine is usually fairly stable; a change in the noise signal may indicate a change in the condition of the machine.

5. Predictive Maintenance

Predictive maintenance is pinpointing when a piece of equipment is likely to fail and addressing it before it happens. Rather than simply aiming to minimize downtime, predictive maintenance aims to maximize uptime. It's an improvement over traditional preventative maintenance approaches because it helps prevent failures in a timely manner.

It's very similar to condition monitoring in that both strategies have the same goal. The difference is that condition monitoring identifies immediate tasks based on monitoring results, while predictive maintenance helps you plan maintenance tasks based on knowledge about overall equipment health and expected performance-knowledge that comes through the gathering and analysis of data.

The Internet of Things makes predictive analytics possible. Sensors attached to your machines and equipment monitor and collect a broad range of operational data, on everything from vibrations, sights, and sounds to temperatures and power consumption. With the help of machine learning and algorithms, this data can then be mined and patterns identified. Eventually, that data can be used to provide valuable insights about aberrant performance that could indicate the likelihood of an imminent breakdown.

As an example of this type of preventative maintenance, consider a commercial refrigerated unit. A manufacturer that owns numerous commercial refrigerated units around the country needs a reliable way to prevent the units from failing because there are high costs associated with failure-including the cost of emergency repairs and product spoilage. As part of a predictive maintenance strategy, the manufacturer could equip each of the refrigerated units with a variety of sensors. The sensors would measure:

Refrigerator temperature

Humidity level

Temperature of the coolant going into and out of the compressor

Temperature of the coolant going into and out of the evaporator

Vibration on the compressor

The number of times the compressor starts and stops

How long the compressor runs

The amount of power the compressor is using

All this data could be stored and analyzed using an Internet of Things platform. Using predictive analytics, it's possible to understand the optimal performance of a refrigerator unit and, when anomalies in the data arise, to determine if and when the unit might fail. The problem can then be addressed before it happens.

Paired with your critical assets, sensors can give you an unprecedented level of insight into your daily operations that supports your equipment-and your building-better than preventive maintenance. Predictive maintenance can significantly reduce downtime, decrease your financial expenditure by prolonging the life of your equipment, and increase the overall safety of your operation.

Would you like to get started with predictive maintenance but aren't sure how? Talk to us at Iota. We can help your company get all the information you need from your important assets so you can predict and prevent failures before they happen.

Our line of IoT sensors enables you to remotely monitor your equipment, providing precise measurements about the aspect of operations you're most interested in. We also offer a subscription-based service of predictive analytics and machine learning algorithms designed to help you optimize equipment performance through fault and anomaly detection. Contact us to get started with better monitoring and management today.

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5 Types Of Preventative Maintenance In Commercial Facilities

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We've talked about preventative maintenance before on our blog, and where it stands on the continuum relative to other types of maintenance. But that's not the end of the story; there are different approaches to preventative maintenance itself, all of which are used to ensure your equipment is operating correctly and potential problems are identified.

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Preventive maintenance

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Autonomous maint.

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Autonomous maintenance increases efficiency by training operators to perform minor maintenance tasks. Below, we discuss implementing autonomous maintenance, sustaining it and more.

What Is Autonomous Maintenance?

Autonomous maintenance is defined as a maintenance strategy where machine operators continuously monitor their equipment, make adjustments and perform minor maintenance tasks on their machines. This is done rather than assigning a dedicated maintenance technician to perform maintenance and regularly scheduled upkeep.

Autonomous maintenance is the first pillar in the total productive maintenance strategy. An operator trained in autonomous maintenance means he or she has complete knowledge of routine tasks like cleaning, lubricating and inspecting. It requires operators to take ownership of their equipment and its surrounding area. This begins by getting the machine to a "like new" standard of clean and keeping it there, ensuring operators are trained on the proper technical skills for conducting routine inspections, and standardizing an autonomous inspection schedule.

Autonomous maintenance follows two core principles:

To prevent equipment deterioration through proper operation, and;

Bringing equipment to, and keeping it at, "like new" status through restoration and proper management.

Much of this relies on operators knowing when a machine upgrade is necessary or when a simple fix can get the machine running again quickly. Autonomous maintenance requires operators to master skills like detecting abnormalities by understanding the machine's components, making improvements, identifying possible quality issues and determining their causes.

With the ultimate goal of total productive maintenance being to enhance your organization's overall equipment effectiveness, there's a reason this starts with autonomous maintenance. It relieves skilled maintenance staff of having to worry about the simple, mundane maintenance tasks, so they can focus on specialized maintenance projects. This leads to multiple advantages like:

Increasing operator knowledge of their equipment

Keeping equipment in a "like new" state, ensuring they are clean and lubricated

The ability to notice emerging issues before they become failures

By allowing machine operators to tackle these routine maintenance inspections and tasks, OEE is further maximized through the reduction of breakdowns and equipment deterioration.

How to Implement Autonomous Maintenance

Implementing autonomous maintenance may vary slightly depending on each plant's operation, but it's typically broken down into seven steps.

1. Increase operator knowledge. Operators might be the master of running their machine to maximum capacity, but for autonomous maintenance to be effective, they need to know the ins and outs of their machine. This involves training from maintenance technicians on the technical details of how the machine's components work and their purpose, as well as training on problem-solving skills. In short, operators should have four equipment-related skills:

1. Detecting abnormalities

2. Correcting and restoring abnormalities

3. Setting optimum equipment conditions

4. Maintaining these optimum equipment conditions

Once these skills are reviewed in a classroom setting, operators can perform basic maintenance tasks on their machines while maintenance technicians observe to ensure everything is covered.

2. Initial machine cleaning and inspection. This step is where equipment is returned to a "baseline" state with the goal of getting it back to a "like new" condition. All hands are on deck for this task, including members of production, maintenance, engineering and operators. Not only is the equipment thoroughly overhauled and cleaned, but the surrounding area is cleaned as well. The goal is to fully restore each piece of equipment to its full performance by identifying and eliminating signs of deterioration. Teams should look for and correct things like:

1. Leaks

2. Loose bolts

3. Proper lubrication

4. Cracks - both apparent and non-apparent

5. Fluid contamination rates

6. Removal of material from water and oil

7. Removal of dust and dirt

8. Conductibility restriction in electrical manufacturing due to oil and/or dust deposits

9. Elimination of stoppages due to dust accumulation

It's a good idea to document the protocol while conducting this thorough cleaning so issues can be easily traced and operators have something to access that contains easy-to-follow steps.

3. Remove the cause of contamination and improve access. Now that the initial cleaning is done and all equipment is restored, make sure it doesn't get to a poor state again. This can be achieved by eliminating all possible sources of contamination and improving accessibility for cleaning and maintenance.
This step also takes safety into consideration. Maintaining a running machine is dangerous, so improving the safety and visibility through better access points is paramount. A popular way to do this is by replacing opaque covers with transparent ones for quick and easy visualization of running parts. Removing the cause of contamination can be done by:

1. Establishing and sticking to cleaning standards.

2. Avoiding soiling. Quality sealing and machine covers are good places to start, but some contamination may only be contained by investing in things like pumps or dedusting - either pneumatically or by dry screening.

3. Promoting cleanliness. Continually reiterate cleanliness during inspections and maintenance.

4. Promoting orderliness. Making sure tools have their place and remain there increases efficiency.

4. Develop standards for lubrication and inspection. This step can be adjusted as needed based on each piece of equipment and its operator. Establishing standards for operators on cleaning, inspecting and lubricating should start with the current documentation on file and end with improved ways to accomplish these procedures. Standards should indicate which components should be cleaned and lubricated, how they should be cleaned and lubricated, and all other maintenance responsibilities to be assigned. Standards will vary based on whether the machine is considered non-critical or critical.

1. For non-critical machines, operators are trained by an experienced maintenance engineer to follow the established standards. Operators can then establish their own routine.

2. For critical machines, a team of maintenance engineers dedicated to maintenance methods can be created to develop standards.

Once finalized, all standards should be documented and made readily available to operators.

5. Inspection and monitoring. Now that they have a set of standards to follow, operators can modify their basic maintenance routine to streamline and improve tasks. The operator's maintenance tasks are tracked and compared with the maintenance department's own schedules (usually through a computerized maintenance management system) to ensure the duplication of tasks isn't an issue. Operators conduct the basic, often-overlooked maintenance tasks such as checking lubrication levels, locating leaks, tightening bolts, looking for impending mechanical issues like cracks and wear, and performing mechanical adjustments like tension measurements, sensor regulation, etc.

6. Standardize visual maintenance. Standardizing autonomous maintenance and making equipment "visual" is an important step for maintaining the integrity of each piece of machinery. How do you make equipment visual? Examples include identifying the flow of fluids through pipes, replacing opaque coverings with transparent ones where possible, labeling the open/close direction of valves and levers, and marking "safe" or "normal" operating values on gauges and sight glasses in green with dangerous levels in red. In short, make things on the machine as obvious as possible.

7. Continuous improvement. Periodically taking the time to step back and dissect standardized processes to see where there is room for improvement is important to ensure you're operating efficiently. Keeping good records of failures is vital to provide data that maintenance engineers can use when designing future machines, making them even easier to access and maintain.
Continuous improvement can also stem from team leaders and maintenance technicians regularly auditing operators' work. Not only does this allow them to point out areas of improvement, but it gives them a chance to congratulate operators on doing a good job.

Sustaining Autonomous Maintenance

Once your operators are properly trained on autonomous maintenance, the procedures are standardized and an auditing system is in place, it's time to focus on sustaining this process. There are a couple of simple tools you can incorporate into your daily routine to help sustain the autonomous maintenance process.

A daily stand-up meeting is a great way for operators and their direct managers to huddle up each morning to discuss how things are going. These meetings work by going around the circle and allowing each person to discuss what is working well and mention any issues they've encountered. Other agenda items include lessons learned, manpower status, management updates, and the day's targets and actions. Daily stand-up meetings might highlight struggles operators are dealing with or introduce changes from upper management that need to be incorporated.

Single-point lessons are excellent for assisting team members to implement changes, helping them not to overlook a step they are struggling to remember or communicate problems that have occurred in the past to prevent them from recurring. One-point lessons generally are focused on equipment subsystems, safety points and basic operating information. An example of a one-point lesson would be creating a stick-on label to be placed directly on a lever or guard to remind an operator who is struggling to remember to rotate the lever or a guard back into the safety position before continuing to the next procedure.

Other steps to sustain autonomous maintenance include:

Track failure and breakdown data: This data is essential when you begin forming your autonomous maintenance procedures. Not only does it guide your operators on which equipment needs the most attention, but keeping track of this data over time lets you track improvement.

Use metrics: Established metrics are the key to monitoring and tracking overall equipment effectiveness in regard to repairs and performance. Analyzing patterns of things like mean time between failures and mean time to repair helps you learn to predict and even prevent future failures.

Document component wear: Use other means to keep track of component wear. Maintenance technologies like oil analysis, vibration analysis and infrared thermography can give you additional insight into equipment failures.

Standardize work order creation: Using work order software helps automate and keep track of work order creation and maintenance data. Software that is integrated with a computerized maintenance management system (CMMS) lets you create a maintenance log sheet for each piece of equipment in your plant. Here, you can record every instance of failure, replacements and when the condition of the components changes.

Benefits of Autonomous Maintenance

Most organizations invest heavily in hiring, training and developing a highly skilled maintenance team to determine why critical assets fail and then repair them. Autonomous maintenance seeks to free up these technicians from performing low-skill tasks like inspections, lubrication and minor adjustments. Among others, there are three major benefits autonomous maintenance brings to an organization.

The biggest benefit is lower labor costs. This includes decreasing inefficiencies related to travel time and waiting for availability. By having an operator who is next to a machine at all times, these types of issues are greatly reduced.

Another benefit of autonomous maintenance is increasing the availability of highly skilled maintenance personnel so they can tend to more critical needs. Employing autonomous maintenance allows even the most tightly staffed maintenance departments to attend to critical issues while not sacrificing routine maintenance.

Finally, autonomous maintenance improves team cohesiveness by eliminating the "we/they" mindset. Traditionally, the operator has an "I use" mindset, while the maintenance technician holds an "I maintain and fix" mindset. Autonomous maintenance shifts this into a more cohesive "we maintain" attitude that fits directly into the pillars of total productive maintenance.

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Autonomous Maintenance: What It Is and Why It Matters

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Autonomous maintenance increases efficiency by training operators to perform minor maintenance tasks. Below, we discuss implementing autonomous maintenance, sustaining it and more. Autonomous maintenance is defined as a maintenance strategy where machine operators continuously monitor their equipment, make adjustments and perform minor maintenance tasks on their machines.