How can you ensure your equipment is operating at peak performance?

Advance plan of keeping the safety stock for the critical spares with longer lead time of A & B class machines will always helps to reduce the down time. Owning my machine concept is always provides better engagement. Weekly / Monthly Kaizen meetings in Gemba by empowering respective employees with timely R&R will produce excellent results to increase overall success for the organization!

very early in my career, my boss told me to "listen to your machinery". Depending on nature of your equipment, you should know what it eats, breaths and the sound, heat etc it creates. Off course you have user manuals and running logs, but "getting to know" your equipment is beyond that. After 25 years, I can say that "it may sound philosophical but it works"

plant Equipment's are design to produce or function with a specific capacity. To ensure peak performance, considering it on production and maintenance perspective. Firstly, the requisite operational and safety trainings must be given to the equipment users. This will guarantee the safe use of the equipment and eliminate operational errors. Secondly, A reasonable production target must be set and monitor the efficiency of the equipment. Looking at the equipment maintenance perspective, the equipment reliability must assured and this can be achieved by conducting failure risk analysis. Develop and implement preventive maintenance plan, develop and implement daily condition monitoring plan, train maintenance team and resource them.

-> Know your equipment and feel it. -> Have dedicated (Maintenance) time at a frequency (daily 15 mins, weekly 30 mins, monthly an hour, etc.) without fail - care your Equipment (A Family Member) Then follow the Points (1 to 6) and more.

A well planned and executed maintenance system is visible in a TPM (Total Productive Maintenance) implemented manufacturing unit. I believe in all the latest of the methodologies, TPM stands up in the way because of its holistic approach to machine maintenance. Machine is considered as one of the most important elements in manufacturing and TPM works towards eliminating "Forced Deterioration" and reducing "Natural Deterioration".This is achieved through daily CLRI/CLIT( cleaning, Lubrication, Retightening & Inspection) and maintenance practices which includes daily maintenance to TBM, CBM and Predictive Analytics. It has a human intervention and the holistic approach of addressing functional elements through multi focussed initiatives.

Read your OEM product manuals. Follow the recommended PM schedule and apply lessons learned. If at all possible always have redundancy (Two is better than one). Mean time to repair is key. Make sure operators and technicians are on the same page (communication). Continuous education is a must.

- Pre-shift checks are very important in ensuring equipment runs at Peak -carrying out preventive maintenance by changing components, harness and part after specified running hours -training technician on the equipment and safe working procedure - ensuring that services are done at manufacturer's schedule time

Je pense que si l'on définit toutes les fonctions importantes pour le client et que chaque fonctions peut étre mesurée. On peut avoir la possibilité de tester chaque fonction. Si chaque fonction est testée, on garantit un produit optimal. Le défi d'avoir un moyen de production de nos équipements (6sigma = 3,4ppm de défaut en produits). Il faut ensuite tester 100% des fonctions de chaque produits (ou pas ?). Ca ferait quand même 3 ou 4 clients déçu sur 96 clients heureux avec un prix correct. C'est un début de réfexion, enrichissez de vos idées :-)

RCM implementation requires ingenuity to work around production schedules. High output departments require critical thinking and solutions to raise reliability and increase bottom line sustainability. Designating areas close to equipment, organized, clean, and policed by planners/coordinators ensuring part availability, maximizes uptime in a reactive prone environment. In today’s landscape, we have more young craftsman than seasoned, which means growing pains and a learning curve is what we’re up against as senior leadership within an organization. Utilizing PdM is critical on high volume equipment because it allows us to schedule planned downtime in the interim to fix things before failure. Thermography, harmonic, and ultrasound testing.

-Mantenimiento predictivo -TPM -Auditoria diaria por el usuario de la maquinaria Seleccionando para empezar con un equipo, ejercitar la practica , depurarla, mejorla, presentarla y mostrar los resultados de como se puede reducir la variacion en proceso. Tener mediciones antes y despues de cualquier implementacion en los cambio de un equipo y proceso es clave para saber si vamos por la ruta correcta

TPM (Total Productive Maintenance) is the key. Using TPM methodology, operators own the machines and keep checking for early warning signs

Monitoring it’s important just be careful of too much data leading to not to much action. A good set of well measured parameters will give you what you are looking for. Example where you have excesive friction theres heat.

Realizar checklist para obter informações de funcionamento e vida útil para ser realizadas manutenções programas para otimização do trabalho

The technology is well advanced and it can be used for condition monitoring. This area of study will definitely provide an insight of issues with the machinery. It is very important to make sure that the input data received from the sensors to measure the data is correct. As we schedule maintenance there must be a schedule for calibration of the same.

The benefits to reliability for condition based monitoring and maintenance are many. The most common cause of failure is “infant death syndrome”. When it has just been installed or repaired and put back together, the most common time for failure is very soon afterwards. By avoiding unnecessary dismantling for preventative maintenance and only having to do it when it is known something is wrong, you reduce these probabilities of failure

Spend the money on the best condition monitoring equipment, assemble an experienced Asset Management and Reliability team to monitor "bad actors". Ensure you're doing the right maintenance at the right time. Go through a Preventive Maintenance Optimization exercise every 5 years to streamline "the right maintenance at the right time", adjust intervals/ frequency of PM's that give the most value/ cost efficiency. Cancel old outdated ( because we've always done this) PM's if no value is found. Finally replace the "bad actors" that are eating your lunch. Spend " smart money" on newer technologies instead of "bad money" constantly repairing older equipment.

I have used this type of technology on pumps, motor and gearboxes, very helpful to anticipate failures , the downside is that you will need trained personnel to interpret data, trends and graphs , or pay for the service, in any case very helpful tool.

Je pense que la faille dans cette réflexion est les capteurs, puisque c' est lui même un équipement avec mtbf, mttr and co.. qui lui aussi devra être surveillé. Une alternative connue mais pas top, vous en conviendrait, c'est de minimiser ou désactiver des fonctions de l'equipement. L'IA et la communauté peuvent nous aider à ça. J'en suis sûr à 100% ;-)

A lot of people will say safety first, preventative maintenance and daily check. Correct that it all about right. Not really. Planning is the first step in all areas of safety, maintenance. Collecting data and understanding the output and input, example let say have forecast of 5000 parts and you have 1 week to do these parts. This is were you start. Plan the production, plan the tool readiness, plan the daily check and plan the service after production. During production do regular checks on safety precautions and all the compliance. Also make sure the employees are skilled in all areas to check for any hidden contributions to wear and tear of tooling, production and the parts. Defects of production can be seen on the part. That my view.

Yes, quality should be first priority. And quality means not a only product quality as well as maintenance quality and machine quality should be maintained as zero condition methods If you do quality maintenance it is reduced risk of failure and increase the machine life. And safety is a not priorit, it is a must to follow because priority can change

All our equipment is inspected by 2 people before it is operated, to make sure that the machine is ok to operate. No machine will be operated unless it passes this inspection, this also includes complying with the regulations and guidelines that apply to our industry. All new members to our team are trained with competent trainers that will show them the inspection process, and the trainer will not sign off on the new member until the trainer is certain that the new member is ready. Not only do we inspect our equipment thoroughly, and train our new members thoroughly, we have quarterly inspections performed by MSHA, this is a very strict inspection that makes sure all aspects of our operation are up to standards.

Me ha resultado útil seguir los protocolos de calidad para la aceptación de piezas y optimizar las cantidades de producción, bajando los tiempos muertos y manteniendo los equipos con las verificaciones de control de calidad siempre encendidas ante cualquier error que se pudiera cometer.

Je ne partage pas cet avis, c'est sans aucun doute et cela devrait être une certitude pour tout le monde : LA PREMIERE PRIORITE D UN ÉQUIPEMENT DOIT ET DOIT RESTER COÛTE QUE COÛTE LA SECURITE DES PERSONNES. La qualité des produits est une priorité d'un point de vue du respect des clients (c"est en antagonisme avec les 3,4PPM que j'ai évoqué dans un autre point..). Un produit défectueux en interne (les rebuts) ou les pièces défectueuses ne peuvent plus être produites. Il semblerait que l'humanité ne saisit pas que nous vivons dans un monde fini. Une piéce défectueuse produite revient à prendre des ressources de la planète pour produire RIEN. Ceci ne peut étre une seconde priorité. L'IA pourrait nous aider à traiter les priorités

Adhering to safety and quality standards in manufacturing ensures a secure workplace, regulatory compliance, and product consistency. It enhances operational efficiency, mitigates risks, and fosters a positive corporate image, opening market opportunities. Continuous improvement principles drive innovation, supply chain collaboration, and employee morale. Meeting standards builds customer trust, ensuring brand reliability. Aligning with safety and quality standards is not just a legal requirement but a strategic decision, offering diverse benefits in workplace culture, regulatory relationships, operational excellence, and customer satisfaction.

The key points for ensuring peak equipment performance, especially regarding safety and quality standards, include the following: Regular Inspections: Conduct routine inspections to ensure equipment compliance. Employee Training: Provide comprehensive training for safety and quality adherence. Documented Procedures: Implement and update procedures aligning with standards. Continuous Monitoring: Utilize systems for real-time performance tracking. Audits and Reviews: Conduct periodic assessments against established benchmarks.

Actually, this should be the first step in the process. Safety should be first and foremost In all manufacturing equipment.

Actually, this should be the first step in the process. Safety should be first and foremost In all manufacturing equipment.

Adhering to safety and quality standards is vital for peak equipment performance. It's not just about compliance; it's about excellence. Training employees in proper usage, handling, and maintenance is as crucial as implementing robust quality control measures. This ensures equipment meets client and stakeholder specifications, reducing risks and errors. Embracing AI and advanced analytics can further enhance this compliance, offering real-time insights and predictive capabilities. Let's champion these standards to not only meet but exceed industry benchmarks! #SafetyFirst #QualityStandards #ManufacturingExcellence #AIinManufacturing

Unfortunately, many companies do not want to reinvest the capital or fund their maintenance departments expense budgets to do updates and upgrades. Sorry to say in my experience, expense budgets are barely enough to keep up with the three essentials; keeping your plant running, keeping your crib stocked and finally keeping your plant and people safe and compliant with safety and environmental regulations and standards. Capital is never assured even when it is part of an approved budget for the year. It can become the victim of a bad first and/or second quarter showing. Worse, companies are very reluctant to approve a capital project they know will not be finished in the current planning year. Even worse, OEM’s cannot deliver in that year.

After P.M. is perform check equípement oportunities by checking cpk capabilities Also ppm are key how many defects per millions of parts are being produced

Once again this stage involves capital investment that a lot of companies tend to avoid because of internal cost reduction politics/requirements. However, in the long term, obsolescence and inefficiency will be more expensive than upgrading equipment as required. On the other hand a good assestment of the equipments that will require upgrades is equally important. Don't waste money when is not needed at all, but invest when (after a proper analysis) is needed.

The lifespan of manufacturing equipment is measured in years or sometimes decades. It typically does not fit in with the modern consumer market/ electronics pace of change. Equipment should be upgraded where practicable however the fundamentals of the equipment are unlikely to be changed so careful selection of the equipment is critical to it being useable for the long term.

The lifespan of manufacturing equipment is measured in years or sometimes decades. It typically does not fit in with the modern consumer market/ electronics pace of change. Equipment should be upgraded where practicable however the fundamentals of the equipment are unlikely to be changed so careful selection of the equipment is critical to it being useable for the long term.

Ensuring peak equipment performance involves proactive strategies. Regular updates and upgrades harness technological advancements, enhancing efficiency and competitiveness. Improved metrics and energy efficiency yield long-term cost savings. Adherence to standards and regulations prevents legal issues. Enhanced safety features in upgraded equipment ensure a secure environment. Adaptability to market demands allows swift responses. Regular maintenance, including software updates, prevents disruptions. Investing in equipment aligns with sustainability goals, fostering operational excellence. A holistic approach, combining upgrades and maintenance, is crucial for sustained peak performance and long-term success.

Persistir na utilização de equipamentos obsoletos no intuito de reduzir custo é o mesmo que negligenciar a manutenção preventiva crendo que ser uma despesa, e não investimento. Na maioria das vezes o prejuízo é o resultado nesse cenário.

From an Instrumentation & Controls perspective, I would add a member to your reliability staff with the sole purpose of identifying equipment that is close or beyond life expectancy and writing notifications for their replacement. Instrumentation is such a specialized field, it seems to get overlooked on route lists and inspections unless it is performed by someone who is an expert in the field.

Updating manufacturing equipment is vital for competitiveness. Embracing new technologies boosts efficiency, quality, and safety, ensuring adaptability to industry changes and sustaining a competitive edge.

Regular upgrades and updates gives more accessibility to new features and also increases overall efficiency and eliminates bugs in the software.

Outra maneira importante, é fazer networking, conhecer outras empresas, mesmo que não seja do mesmo segmento, mas aumentar o leque de conhecimento de técnicas e equipamentos existentes. Buscar novidades, visitar fabricantes para estar sempre se atualizando.

Get your team engaged with ownership of the process. Have enough staff so everyone can become an expert and know what is out of the normal. A seasoned instrument tech with 5 years of experience on a process is far more valuable to you than an Engineer out of school. Empower your tradesman to perform with their full skillset and you will be successful.

PDCA serves as a paramount management method essential for every continuous improvement initiative in processes, products, or services. After the aforementioned recommendations are put into action, a continuous cycle of checking and acting is imperative. This iterative process ensures ongoing refinement, potentially requiring an extra push or specific requirements to optimize efficiency and harness the full potential of the accomplished improvements.

Nesse processo de feedback é possível consultar empresas especializadas em manutenções mais avançadas, para efetuar um mapeamento melhor da condição de seus equipamentos, pois as mesmas possuem ferramentas que muitas vezes não são utilizadas no dia a dia da manutenção, exemplos, Termografia, Análise de Vibração, Estudo de Lubrificação, Análises de óleo entre outros.

Os feedback e benchmarks são essenciais para busca da melhoria continua do processo de manutenção, pois cada operador conseguirá contribuir para o avanço do processo. Métricas e KPI's bem direcionados orienta a equipe e a Qualidade da Manutenção ( QM ) será eficiente

Regularly check the equipment for evaluating the performance and check in a timely manner to calculate the effectiveness in different times and situations.

The fifth step of soliciting feedback for optimal equipment performance is key. Regularly monitoring and evaluating performance against benchmarks is crucial. It's equally important to seek insights from operators, technicians, customers, and suppliers. Their perspectives can unveil gaps, issues, and areas for improvement. Implementing necessary changes based on this feedback is not just a task; it's an opportunity for innovation and excellence. Embrace this process as a journey towards continuous improvement and excellence in your equipment performance. #ContinuousImprovement #FeedbackCulture #EquipmentExcellence #InnovativeThinking

Yes, all feedback and benchmark are important to improve our equipment performance. We need to have excellent measurement on that.

In my experience, a Lean Management approach may provide the best environment and organisational tools to get a 360° support and tracking KPI’s and potential issues arising.

Establecer una tabla de indicadores reales que brinden información clara de si un programa de mantenimiento está realmente teniendo éxito en por ej, disminuir la tasa de fallas de un equipo, es fundame para establecer criterios para decidir si vale la pena la inversión en un programa de manten en específico.

Best practices allow one to eliminate unnecessary PMs, reduce PMs to increase efficiency and increase PMs for things that impact efficiency.

Benchmarking and Best Practices Replication is a cooperative approach to improving operations with several advantages: - provides quick boost - teams get more empowered checking at first person how they can perform as well as best in class. - creates collaborative networks between professionals to keep a spinning flywheel for future improvements.

Best practices always help to improve maintenance plan and activities to reduce maintenance time. Also it is increasing knowledge of employees specifically maintenance performer for get best quality maintenance with less time spent

Many companies use only a small percentage of the technology in which they invest. The latest tech usually involves internal change, and we know this can be difficult. When companies push their resources they are usually rewarded with increased market share.

As someone who has seen a lot of DIY solutions implemented on various production lines - most of this solutions are quite dangerous as they create an illusion that a problem has been fixed when in reality it is still there and is destroying your machine little by little every minute it is turned on. Or it has created a brand new problem that is doing the same thing. Professionals and their solutions might be expensive, but not as expensive as a new machine. Invest in them, its the best investment you can make.

Definitely a good resource specially in large organizations where you can contact colleagues from different sites and is less likely that there will be communication barriers as you are under the same umbrella, compared to smaller organizations where there the information and Knowledge is not that easily shared.

Share and seek for best practices in the industry, educate yourself and your crew, stay on top of technology trends and most of all train your crew constantly.

Sem dúvida a comparação gera um novo nível de senso crítico do processo e também a melhoria continua. Porém a implementação de novas soluções precisa ser realizada de forma estruturada. Em muitas situações geram-se novos problemas ao tratar problemas antigos.

To enhance equipment performance, embrace best practices. Research industry standards, network with experts, and attend relevant events to gain insights. Collaborate with peers and stay updated on maintenance strategies. Learning from best practices ensures the adoption of effective methods for optimal equipment functionality.

Define, validate, and monitor key process performance drivers and indicators. Catch process variation before it drives product variation.

Implement Computerized Maintenace Management Systems like EAM or SAP to optimize spare parts inventory and easy planning and scheduling

Housekeeping practices are paramount. If you do not have sufficiant lighting or routine cleaning of your operation spaces, you will not be able to identify issues before they become a problem. An example would be a small oil leak that you can't see from something until the gearbox fails or air filter systems covered in dust so you are unable to see that a filter was missed on a route and it has caused you to loose pressure, aka loss of valve control.

A simple thing to do is implement TPM approach. Total productive maintenance(TPM) is a method of managing assets for its maximum efficiency and effectiveness there by optimize the operating costs and enhance operational excellence. The key outcomes you can expect are 1. Increased OEE(which is an essential KPI for the manufacturing operations) as it contributes to all the 3 factors of Availability of equipment/asset, performance efficiency and quality of the parts/outputs. I have successfully implemented this in multiple manufacturing organizations. It does wonders. The beauty is, it all start with ownership from the operating people(my machine mindset). Even I have deployed in offices. To learn more, read out 8 pillars of TPM.

Make sure you’ve planned for enough redundancy and available capacity for upgrades. Workhorse assets can become obsolete ticking time bombs when they’re too valuable to be shut down for an upgrade

1,Proper training of machine operators to ensure proper machine operation because they are the ones who are handling the machine all the times. ☆Train operator on distinguishing good sound and abnormal sound and encourage them to report immediately. ☆Train operators proper torque application when doing tool change or operational settings on the machine to avoid screw breakage and screw holes loose threads. ☆Educate operator on proper handling of toolings to avoid untimely replacement off tooling formats. ☆Involve operators on doing PM for training and keeping moral high because they learning new skills.

One thing I've found helpful is to use high-quality lubricants and parts. Using the right lubricants can significantly extend the lifespan of your equipment, minimize downtime, and improve overall efficiency.

Figure out how much production capacity you need from each piece of equipment. Take not only the production cycle time into account, but downtime, slowtime, maintenance time (planned & unplanned--and include parts replenishment and the availability of the technicians needed to do the work), time equivalent of defective product, time equivalent of bad parts being received at the machine, the whole shooting match. You need to shoot for a balanced line, not single pieces of equipment that will generate more internal WIP.

keep the philosophy of detailed defect/damage assessment a must do within the operating and maintaining personnel as it helps classifying and troubleshooting the defect in your equipment, as well as prediction of what might happen in the future. A continuous liaising with the OEM of the equipment might reveal other users similar sufferings that might help the OEM's engineering resolve issues.