How can you maintain equipment for maximum efficiency and productivity?

Maintaining equipment for maximum efficiency and productivity involves several key steps: 1. Regular Inspections 2. Scheduled Maintenance 3. Lubrication 4. Cleaning 5. Calibration 6. Repairs 7. Record-Keeping 8. Training 9. Storage 10. Replacement Parts 11. Safety Measures 12. Upgrades and modernization 13. Predictive Maintenance 14. Energy Efficiency 15. Continuous Improvement By following these practices, you can maximize the efficiency and productivity of your equipment while extending its lifespan and minimizing downtime.

It is important to implement Reliability Based Maintenance in plant which includes schedule maintenance based on identified criticality if equipment, training to employees, records of all maintenance activities, Monitoring performance and Upgradation when required.

In my experience, regular visual inspections can be the most important part of maintaining equipment. Knowing what the equipment normally looks and sounds like can help you detect equipment problems as they arise. Preventative maintenance and schedules are great, but knowing when a something is running differently can help you find problems before they become major issues.

-Tambien es interesante tener material fungible para mantener el equipo en perfecto orden de uso. -En el caso de equipos sencillos o convencionales es interesante tener recambios de las piezas de desgaste, incluso algun equipo completo en backup para posibles roturas. -En el caso de equipos industriales lo ideal es contar con un servicio de revisiones periodicas y reparaciones externalizado y de buena calidad.

Never skip preventive maintenace schedule or task. Preventive maintenance is important to avoid major failure on the equipment. Preventive maintenance also should be revise through the year as machine getting older.

Weekly Meetings conducted with Fleet Manager and Operational Staff identifying with a preventative maintenance plan agenda along with servicing agenda to coordinate Routine Maintenance.

To maintain equipment for maximum efficiency and productivity, here are guidelines to follow: Scheduled Maintenance: Create a maintenance schedule based on the manufacturer's recommendations or industry best practices. This includes preventive maintenance tasks such as replacing filters, lubricating moving parts, calibrating instruments, and conducting system checks. Lubrication: Keep equipment properly lubricated as per the manufacturer's guidelines. Lubrication reduces friction, minimizes wear and tear, and ensures smooth operation. Use the recommended lubricants and follow the specified intervals for reapplication.

Operating equipment within safe limits as advised by vendors is also critical to run it for longer time without unwanted stops

I have found that following the manufacturers suggested preventative maintenance schedule is a great start to a never ending job. In past experiences, I have also used “risk areas and factors” that coincides with predictive maintenance. Excel works wonders if you have multiple machines that have preventative maintenance deadlines, as well as tracking replacing fluids and calibration times.

This is the most important point. Know your job and what to do when things don’t go as planned. There will be hiccups. How you respond determines if you will have a happy customer or not

To maintain equipment for maximum efficiency and productivity is Training and Operator Care: Train operators and personnel to handle equipment properly, following established procedures and safety guidelines. Encourage operators to report any issues or abnormalities promptly. Proper usage, handling, and storage can significantly extend equipment life.

Agree. Human is most important factor for maintenance. Company must adequate technician with proper training, enough tool, PPE, so they able to perform job without hassle. Keep refresh training to your team. It's good to always a session with them and let them share their experience or difficulties performing daily task.

As I mentioned above regarding Jishu Hozen, herein the field operators and staff can be trained in an easy and effective way to inspect and abnormalities in a particular area, employing a number of checklists, which can be easily verified with respect to inspection points marked on the equipment

Between permanent operators and temporary operators, training can be the single most important part of using the machine. A permanent operator may be able to tell the difference if a machine is making an abnormal noise or shake, but a temporary operator may not. That is why it is important to train staff that may be in any area of the machines to grasp the basic concept, how it operates, and how to disengage the machine in an emergency situation.

To maintain equipment for maximum efficiency and productivity is Component Replacement and Monitor the lifespan of critical components and replace them before they fail. Keep an inventory of spare parts and consumables to minimize downtime. Follow manufacturer recommendations for component replacement intervals or consult with experts in the field.

It is true. Spare part availability is important to make sure no delays in repair job. You must have enough inventory to keep machine running, set a safety level for your part and immediate replenish when it reach safety level. It's good to have key person to focus and properly manage the spare part inventory.

Spare parts, tools and other supplies should always be kept arranged and should be marked so as to enable even a common man to see and pick up the correct tools and spare as and when required(just an example to how required information should be clearly mentioned with respect to every tool/spare

The proper maintenance strategy and guidance will need to in place to ensure the approach for different spare parts - Especially for the critical few Vs. non-critical but high consumption rate ones. Regular review the parts usage data and equipment historical report to see the pattern and understand why breakage is occurring through proper problem solve as well.

In a post Covid business environment its more important than ever to manage spare parts and supplies. Across the board our vendors are keeping less in inventory and we hear the part is available tomorrow or later when they used to keep it on hand. You have to increase critical spares and build your supplier network because production can't just stop for 24 hours every time something breaks.

One thing that help me is always list down common problem with your equipment. - what is the problem? - what is the root cause? - how to solve the problem? - what part need to be replace. So you can analyze later and determine if this problem can be avoid with include task during preventive maintenance

Exactement En combinant ces approches vous pouvez non seulement résoudre les problèmes courants mais aussi améliorer globalement la performance et la fiabilité de vos équipements

What is happening? How is it happening? Have we tried anything to fix it? How did that work? What do other companies do to solve this? What would it cost to eliminate this issue? Use this script to flush out what supplier can help you the most!

Common Issues: Are often unresolved or repeat items. But these common items are often due to poor tracking and a lack of legacy or what I've heard referred to as organizational memory. You often hear people say "this is the third time this year that has happened" or "this exact thing happened last year". Continuous turn over in key positions is one major problem. Without legacy? No one follows through on the corrective actions needed to stop repeat issues. No one with the authority to act "remembers" seasonal changes or adjustments needed. And here we go again...

Creo que más allá de buscar ayuda especializada, es tener personal calificado en la solución de problemas, en el análisis de causa raíz, en mi experiencia muchas veces se contratan empresas y resuelven el problema pero al cabo del tiempo estos problemas vuelven, y la empresa hace un un trabajo de calidad pero la raíz de la avería no fue resuelta, hay que tener personal calificado en análisis para poder dar un mantenimiento eficaz no solo en prevenir y/o corregir fallas, sino también en realizar ese mantenimiento que a mi criterio molesta mucho a nivel corporativo el Mtto predictivo.

Train the Team to meet excellence in operation & Maintenance. Focus on continual improvement Focus on Energy saving techniques Focus on sustainability and GHG initiatives

No cometamos el error que querer solucionarlo todo nosotros por nuestra cuenta. Siempre puede haber problemas que superen nuestro conocimiento y capacidades, y no es para sentirse mal. Para no perder tiempo y exponerse a empeorar la situación sugiero siempre consultar con personal idóneo o con mayor conocimiento del tema.

You can do by Regular testing and inspection. Planning and executing regular maintenance during annual turnaround. Running the equipment at optimum parameters. By not utilising robust override procedures. Conducting refresher training to the equipment operators and supervisors on regular basis. By carrying out LLF technique on machines.(Look, Listen and Feel) By using only onspec materials through the machine not running on any offspec or contaminated material.

1. There are some specialised equipment and systems like Process Analysers, Condition Monitoring and DCS for which comprehensive AMC by OEM is required for trouble free performance. Identify such items and arrange for OEM support. 2. Some equipment need replacements or upgrades on account of obsolescence. Computerised systems like servers, operator and Engineering work stations need frequent upgrades. Identify such needs and address them promptly. Cyber security demands are growing day by day. 3. Carry out Periodic calibration of I&C systems to maintain accuracy and precision in performance.

If a plant is not designed properly to sustain the required process flow conditions, it will experience frequent equipment breakdown that would lead to a reduced lifespan no matter how the maintenance strategies are reviewed. Most of the contributions to equipment failure are process or production related challenges to an extent that safety devices also fail to protectthe system. For any extensions required to improve the production target, rerating procedures have to followed fully to prevent unnecessary turbulence within the system and in this case, the strategies put in place would be efficient enough to keep an equipment beyond its lifecycle and reduce breakdowns.

Getting to know the equipment and its proper operation is key. Watching the timing, tracking and other key areas will help the mechanic have a better understanding of how the equipment is running.