Conoce cómo crear un plan de mantenimiento preventivo para tu empresa.

Introduction to Preventive Maintenance

Opening Remarks

• The webinar begins with a welcome message, encouraging participants to communicate any technical issues.

• The speaker introduces the topic of preventive maintenance, emphasizing its importance for various machinery and equipment used in businesses.

Importance of Preventive Maintenance

• Genesis Puentes, an industrial engineer at Konami P, highlights that many companies only perform corrective maintenance when critical machines fail.

• This reactive approach can lead to production delays and potential penalties for not meeting deadlines.

Understanding Maintenance Concepts

Definitions and Types of Maintenance

• The agenda includes discussing basic concepts of maintenance, types of maintenance, and the significance of having a maintenance plan.

• Maintenance is defined as actions taken to ensure that equipment operates as designed within an industrial process.

Involvement Across Departments

• Effective maintenance requires collaboration across various departments such as sales, production, quality control, and logistics.

• All areas must recognize the importance of maintaining equipment to achieve operational efficiency and meet performance indicators.

Key Components in Maintenance Planning

Understanding Equipment Terminology

• A humorous definition states that maintenance is often overlooked until something goes wrong; then everyone agrees it’s essential.

• Key terms are clarified: accessories (complements), components (parts forming circuits), machines (resistant materials with defined movements), and mechanisms (relative movements).

Reliability and Availability

• Reliability refers to a machine's ability to perform required functions under specified conditions over time.

• Availability indicates how often a machine is ready for use without interruptions during its operational period.

Understanding Maintenance Types in Industrial Operations

Reliability and Availability

• The concept of reliability and availability is crucial for calculating the percentage of time a machine or equipment is operational and ready to perform its designed function.

Types of Maintenance

Corrective Maintenance

• Corrective maintenance, also known as reactive maintenance, is predominantly used in many developing countries. It occurs when a machine fails and needs immediate repair to resume operations.

• This type of maintenance aims to minimize downtime by quickly repairing or replacing faulty components, although delays can occur if parts are sourced from distant locations.

• Many companies rely solely on corrective maintenance due to a lack of knowledge, tools, qualified personnel, budgets, or modern technologies for other types of maintenance.

• Disadvantages include unpredictable production schedules and potential for more severe damage if failures go undetected. Additionally, it can lead to reduced equipment lifespan due to repeated failures without proper diagnosis.

Preventive Maintenance

• Preventive maintenance involves planned activities carried out at defined intervals aimed at ensuring that company assets operate efficiently and prevent failures before they occur.

• This approach helps avoid production stoppages caused by equipment failure and reduces costs associated with corrective maintenance by addressing issues proactively.

• Benefits include decreased anomalies or failures leading to increased machine availability and extended lifespan of equipment through regular upkeep activities. It also results in cost savings over time by minimizing expensive repairs and part replacements.

Predictive Maintenance

• Predictive maintenance relates physical parameters with the wear state of machinery; it allows for timely interventions based on actual condition rather than scheduled intervals alone.

• There are two forms: programmed corrective maintenance (scheduled when components show signs of impending failure) and unprogrammed corrective maintenance (reacted upon unexpected breakdown). Understanding these distinctions helps organizations better manage their resources effectively while reducing downtime risks associated with unplanned repairs.

Understanding Predictive Maintenance

Importance of Equipment Availability and Reliability

• The focus is on increasing equipment availability and reliability through planned tasks, which are executed within defined periods to enhance operational efficiency.

Predictive Maintenance Overview

• Predictive maintenance involves analyzing physical parameters related to machine wear or condition, allowing for proactive measures before failures occur. This approach anticipates issues rather than merely reacting to them.

Techniques in Predictive Maintenance

• Various analyses such as ultrasound testing, combustion analysis, thickness control in static equipment, vibration analysis, thermography, and oil analysis are employed to predict machine failures effectively.

Preventive vs. Corrective Maintenance

• While predictive maintenance does not replace preventive maintenance, it can reduce the need for corrective actions by addressing potential failures ahead of time.

The Necessity of a Preventive Maintenance Plan

Objectives of Preventive Maintenance

• A preventive maintenance plan is essential for avoiding costly repairs and ensuring machinery operates efficiently over time. It serves as a management model that outlines necessary resources for effective maintenance.

Key Reasons for Implementing Preventive Maintenance

• Six reasons highlight its importance:

• Reduces unexpected downtime by improving equipment availability.

• Extends the lifespan of assets by maintaining optimal operational levels.

• Enhances overall effectiveness leading to more accurate forecasts regarding production capacity and revenue.

• Lowers economic costs associated with corrective maintenance due to fewer urgent repairs.

• Increases understanding of facility strengths and weaknesses through data collection on recurring failure causes.

• Improves stock planning and human resource allocation by adjusting inventory based on availability.

Steps to Develop a Preventive Maintenance Plan

Constructing the Plan

• Five steps are outlined for creating an effective preventive maintenance plan:

• Determine objectives that align with company goals and how they will be measured in the future.

• Conduct an inventory of all machines and equipment within the organization.

• Assess available resources necessary for executing the plan effectively.

• Codify and structure collected data systematically.

• Execute the plan while continuously measuring outcomes for ongoing improvement.

Objectives and Strategies for Maintenance Management

Key Objectives in Maintenance Management

• The primary goals of maintenance management include reducing the number and costs of failures, increasing machine uptime, improving human resource efficiency, and minimizing workplace accidents.

• Companies must tailor their objectives based on past experiences; for instance, a company that has faced severe consequences from corrective maintenance may prioritize reducing workplace accidents.

Establishing Indicators for Success

• To measure the effectiveness of maintenance plans, specific indicators should be established. Examples include planned maintenance percentage, mean time to repair (MTTR), unplanned downtime duration, mean time between failures (MTBF), and maintenance delays.

Asset Inventory Management

Hierarchical Structure of Equipment

• Conducting an asset inventory involves creating a hierarchical structure that defines relationships among equipment. This helps in understanding production cycles and how machines interact with each other.

Technical Information Requirements

• It is crucial to obtain technical manuals from manufacturers or suppliers for all equipment. This includes operational manuals, parts breakdowns, and historical maintenance records.

Classification of Critical Equipment

• Identifying critical equipment is essential; these are machines whose failure would halt operations entirely. An inventory should be maintained detailing all equipment needing maintenance along with warranty periods.

Resource Determination for Maintenance Activities

Defining Maintenance Tasks

• The next step involves defining specific tasks required for maintaining machinery. This includes determining the frequency of these tasks based on their importance to operations.

Data Collection and Historical Context

• Collecting technical data about machines is vital. This includes manufacturer manuals and historical maintenance records which inform preventive measures based on previous corrective actions.

Structuring Data for Effective Maintenance Planning

Codification Process

• After establishing objectives and analyzing tasks, it’s important to codify data related to equipment and tasks. This facilitates organized tracking within a management tool or spreadsheet.

Execution and Continuous Improvement

• The final phase involves executing the plan while measuring its effectiveness through regular supervision according to established frequencies. Continuous improvement is necessary based on performance evaluations against set objectives.

Maintenance Planning for Universal Lathes

Importance of Continuous Improvement

• Emphasizes the necessity of regular maintenance checks, akin to lubricating a machine weekly, to ensure operational efficiency and measure results against predefined objectives.

• Highlights the significance of maintaining an open mindset towards continuous improvement, suggesting that questions often arise during the execution phase of preventive maintenance planning.

Overview of Universal Lathe Maintenance

• Introduces the universal lathe as a critical tool in mechanical workshops, known for its ability to shape cylindrical workpieces through rotation and cutting tools.

• Describes how the lathe operates by rotating a mounted piece while applying a cutting tool against its surface, detailing the interaction between components like the tool holder and tailstock.

Developing a Maintenance Plan

• Stresses understanding the machine's operation and identifying its main parts—bed, fixed headstock, movable headstock, tool carriage, and movement transmission devices—as foundational steps in creating an effective maintenance plan.

• Discusses establishing nomenclature for each part using initial letters from their names followed by numerical identifiers to streamline inventory management.

Technical Specifications and Documentation

• Presents an example document created for a metalworking company requiring a maintenance plan due to past failures affecting customer orders; emphasizes documenting technical specifications provided by manufacturers or suppliers.

• Details essential technical data such as photographs, general specifications, dimensions (e.g., turning capacity), and internal components' details necessary for effective repairs.

Inventory Management

• Explains how having comprehensive knowledge about machine parts is crucial for repair processes; highlights potential issues arising from lack of information on damaged internal components.

• Outlines how physical inventory is categorized based on electrical circuits with specific codes assigned to various elements like timers and motors for efficient tracking.

Inventory and Maintenance Planning for Machinery

Importance of Inventory in Maintenance

• The inventory process involves detailing specifications such as screw type, length, diameter, and quantity to understand machine components.

• Knowing the machine's parts is crucial for constructing a maintenance plan; without this knowledge, effective maintenance cannot be provided.

Historical Data Utilization

• A historical record of machine failures is maintained in an Excel format, documenting details like failure dates, descriptions, downtime, production loss hours, and repair costs.

• This historical data helps identify recurring issues by providing insights into previous repairs and their durations.

Technical Specifications Overview

• A technical summary includes essential details about the machine such as model type (e.g., universal parallel lathe), dimensions, weight, power rating, and frequency.

• Dividing machines into systems and subsystems aids in assigning specific preventive maintenance activities tailored to each component.

Breakdown of Machine Components

• For example, a 7.5 hp lathe has an electrical subsystem with components like motors and relays; understanding these allows for targeted maintenance strategies.

• Each subsystem contains various mechanisms (e.g., transmission mechanisms), elements (e.g., bearings), and accessories (e.g., screws), which are critical for comprehensive maintenance planning.

Structuring Preventive Maintenance Activities

• The approach involves defining mechanisms first before identifying elements and accessories within each subsystem to ensure thorough coverage in the maintenance plan.

• With complete knowledge of technical data, historical records, and part inventories established earlier in the process, one can confidently define preventive maintenance activities without overlooking any necessary components.

Maintenance Planning and Implementation

Importance of Preventive Maintenance

• Preventive maintenance is crucial to avoid corrective maintenance; neglecting elements can lead to increased failures.

• A comprehensive understanding of all components involved in the maintenance plan is essential for effective implementation.

Structure of the Maintenance Plan

• The preventive maintenance plan includes key details such as department, approval date, and machine name (e.g., parallel lathe).

• Specific tasks are outlined within the plan, detailing their frequency (e.g., oil changes every six months).

Task Frequency and Types

• The maintenance plan consists of 25 activities, primarily annual tasks followed by semiannual, quarterly, and monthly tasks. Examples include lubrication and inspections.

• Activities like checking the gearbox will be conducted annually; a checklist format allows for observations during these checks.

Daily Checklists and Responsibilities

• Daily checklists are vital for monitoring equipment condition; they cover electrical systems, oil levels, and mechanical components. These should be completed at the start and end of shifts.

• Operators should ideally perform these checks to ensure accurate reporting on machine conditions (e.g., oil levels). Observations must be documented meticulously.

Addressing Anomalies Promptly

• Immediate action is required if any anomalies are detected during daily checks to prevent further damage or operational downtime. This proactive approach minimizes reliance on corrective maintenance.

Activity Calendar and Follow-Up Support

• An activity calendar outlines scheduled tasks along with responsible personnel; it helps track costs associated with machine downtime due to maintenance activities.

• Participants are encouraged to share their email addresses for editable formats of the templates discussed, facilitating easier implementation in their operations. Additional support may be offered through personal meetings for tailored advice on specific machinery needs.

Maintenance Planning and Predictive Techniques

Overview of Maintenance Plan Development

• The speaker emphasizes the importance of sharing auxiliary information to construct a comprehensive maintenance plan.

• Specific interest is noted in understanding machine components, particularly screws and their nomenclature, which varies by machine type.

Importance of Machine Knowledge

• Understanding the parts that make up a machine is crucial for planning maintenance activities effectively.

• A reference is made to using thermal cameras in preventive maintenance to monitor electrical component temperatures.

Predictive Maintenance Insights

• Predictive maintenance involves using equipment to assess the operational status of machines and preemptively address potential failures, such as monitoring vibration levels.

• Various analysis methods are mentioned for predictive maintenance, including mechanical vibration analysis, oil analysis, and thermography.

Challenges in Implementing Predictive Maintenance

• The speaker notes that few companies in the country implement predictive maintenance due to a lack of awareness about equipment criticality.

• An example from a water bottling company illustrates how critical equipment (like pumps) can halt production if not properly maintained.

Conclusion and Contact Information

• The session concludes with gratitude for attendance and mentions that presentation materials will be sent via email.

• The speaker offers contact information for further inquiries regarding preventive, predictive, or corrective maintenance strategies.