Equipment service (maintenance): a combination of equipment repair and maintenance. In order to prevent deterioration of equipment performance or reduce the probability of equipment failure, technical management measures are carried out in accordance with the provisions of the pre-specified plan or the corresponding technical conditions.
concept
Equipment service (maintenance): a combination of equipment repair and maintenance.
In order to prevent deterioration of equipment performance or reduce the probability of equipment failure, technical management measures are carried out in accordance with the provisions of the pre-specified plan or the corresponding technical conditions.
When the production line equipment fails, the operator needs to promptly notify the equipment maintenance personnel to come to the maintenance. Generally, the workstation is equipped with a point-and-click wireless alarm button.
The equipment maintenance personnel carry the point extension mobile bp machine. When the equipment is faulty, the operator can immediately receive the alarm information to the fault scene by pressing the button.
Maintenance of production line equipment, generally equipped with production line equipment abnormal kanban, mechanics and leaders can intuitively and timely understand the status of production line equipment.
idea
Maintenance and repair of equipment, if only started when the problem occurs, will lead to low production capacity and quality, and lose competitiveness.
Therefore, it is necessary to decide some basic ideas of maintenance and then group them:
The basic methods are as follows:
Post-maintenance (BM: Breakdown Maintenance)
Preventive maintenance (PM: Prevent Maintenance)
Production Maintenance (PM: Productive Maintenance)
Total Productive Maintenance (TPM: Total Productive Maintenance)
Predictive Maintenance (PdM: Predictive Maintenance)
State Based Maintenance (CBM: Condition Based Maintenance)
stage
In Japan, the gradual process of equipment management is divided into the following five stages:
(1) Stage 1 After-the-fact maintenance
What was done before 1950 was BM: Breakdown Maintenance. The idea is: wait until it is broken and then repair, even now, when the stop loss of the production equipment can be neglected, you can take the after-care program. If the occurrence of repair work is sudden, it is very difficult to make a plan beforehand. Therefore, it is easy to be disadvantageous to the distribution and arrangement of personnel, materials and equipment. However, from the point of view of productivity to comprehensiveness, if this efficiency can be ignored, post-maintenance can be used.
Also, when the mean time between failures (MTBF) is not constant, the mean repair period (MTTR) is short, and it is expensive to perform part exchanges on a regular basis, and in this case, after-the-fact maintenance can also be taken.
(2) Phase 2 Preventive Maintenance
Preventive Maintenance (PM: Prevent Maintenance) was introduced to the United States around 1950. This method is to perform maintenance before the device fails.
Preventive maintenance is a method used to prevent downtime caused by sudden failure of equipment. It is a maintenance method that replaces parts or a unit according to economic time intervals.
The interval between preventive maintenance depends on the size or life of the equipment. It can be checked or repaired or overhaul once a year or once every six months or once a month or once a week.
Preventive maintenance is not economical if it is too much. We plan to prevent maintenance based on the after-sales repair costs or the comprehensive production and production targets and the rate of activity.
(3) Stage 3 Production Maintenance
In the 1960s, it was considered to use PM (productive maintenance). This is the most economical and good maintenance method to ensure the productivity of the equipment. This method is a way to combine the cost of the device (LCC: life cycle cost) or the cost of maintaining the device with the deterioration of the device and the Justification, and then decide how to maintain it.
There are two ways and ideas:
1. Improved maintenance (CM: correct maintenance)
In order to make the maintenance and repair of the equipment easier, it is further said that the equipment can be improved in order to make it unnecessary to repair and maintain, that is to say, the technical improvement of the equipment by improving and improving the productivity of the equipment.
2, maintenance prevention (MP: maintenance prevention)
In order to fundamentally reduce the maintenance cost of the equipment, instead of just considering how to maintain it, it is better to manufacture equipment that does not require maintenance or to consider maintaining it when purchasing. This kind of idea can achieve the smooth and economical adjustment and maintenance of the equipment to the maximum extent, which is called maintenance prevention.
(4) Stage 4 TPM
Since 1970, it has entered a company-wide production maintenance (TPM: total productive maintenance) that includes small group activities that are independently organized by operators.
In 1971, Nippon Denso published an article entitled "Production and Maintenance (TPM) for all employees." It is pointed out that production prevention (maintenance) is not only the responsibility of the office person, but also a Total-type preventive prevention of all the company-wide management, management and operators.
The management layer is the person responsible for promoting production and maintenance. All the operators must participate in the activity with enthusiasm. Even if it may not be mature and perfect, this is already the symbol of the birth of the innovative TPM activity.
(5) Stage 5 Predictive Maintenance
It is the pre-emptive maintenance (PM: predictive maintenance) that began to spread in the 1980s. Predictive preservation is the concept of diagnosing the deterioration or performance of a device and then performing maintenance and maintenance activities based on the diagnosis. Therefore, it is a prerequisite to grasp the deterioration of the equipment as accurately and accurately as possible.
The state of deterioration (CBM: condition-based maintenance) is observed when the state of deterioration is observed and when maintenance is really necessary.
With the gradual grasp of the condition of the equipment and the improvement of the equipment fault diagnosis technology, it has recently come to the judgment and countermeasures based on the time-based inspection, inspection, and repair to the state of the equipment.
Time-based is called time-based maintenance (TBM) or planned maintenance.