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Top 10 Best Maintenance Practices for Manufacturing Plants

Planning to produce is generally reactive. It depends upon critical market forces like demand and supply. But, production and maintenance always need to be proactive. A production line can only work well if it can detect oncoming problems beforehand. Efficient units have provisions to rectify those problems before the real breakdown takes place. To explore more, visit: https://www.downtimecollectionsolutions.com

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Top 10 Best Maintenance Practices for Manufacturing Plants

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  1. TOP10 BEST MAINTENANCE PRACTICES FOR MANUFACTURING PLANTS

  2. FOCUS ON MAKING THE MANUFACTURING PLANT PROACTIVE

  3. Planningtoproduceisgenerallyreactive. It dependsuponcriticalmarketforceslikedemand andsupply. But, productionandmaintenance alwaysneedtobeproactive. Aproductionline canonlyworkwellifitcandetectoncoming problemsbeforehand. Efficientunitshave provisionstorectifythoseproblemsbeforethe realbreakdowntakesplace.

  4. Sadly, around90% manufacturingunitsinthe USarestillreactivein nature. Theyonlytake actionwhenanunplanned downtimeoccurs. This causesbigdentintothe productivityoftheplant andleadstogreatlossof laborandproduction.

  5. Unplanned Downtime is Preventable Unplanneddowntimescausepanic, hasteand pandemonium. Theproductiontakesabighitanda largeamountoftimeislostinarrangingtechnicians andspares. Faultylabor, oldmachinery, unavailability ofspares, andotherthingslikethesetaketheblame.

  6. Themostunfortunatefactis, mostofthetimeyoucan preventthem. Moderntechnologyismakingprogress byleapsandbounds, theneedofthehouristotake advantageofit. EquipmentDowntimeTrackingand MachineMonitoringtechnologiescanavertsuchevents toagreatextent. Theyareinexpensive, easytouseand veryeffective.

  7. Invest in Proactive Maintenance PredictiveandProactiveMaintenanceistheneedofthe hour. YoucancarryitoutwiththehelpofManufacturing DowntimeTrackingmechanismavailabletoday. Fully computerizedandautomatedmachinemonitoring systemsarethere. Theytrackandforecastevenminute errorsandrepairrequirements. Theyreporteachand everyerrorinrealtimesothatseriousbreakdownsdonot takeplace. Theyprovideeasytounderstanddataandalso presenthistoricalstatisticsforthemachinefailures. The errorsarecolourcodedandspecific.

  8. MaintenanceManagementisaveryignoredpartinthe productionlines. Usually, themachinesareusedbeyond theircapacityinthepeakseasonsandonlyrepairedwhena breakdowntakesplace. Ironically, thisdoesn’tboostthe productioninanyway. Infact, whenanimportant machinerybreaksdownsuddenly, italsoaffectsthe subsequentmachinesintheassemblylinedependentonits production. Ifanymanufacturingunitwantstoachieveoptimal production, itwillhavetofocusonproactivemaintenance. IncreasingtheOverallEquipmentEfficiency (OEE) isthe onlywaytogetridofthisproblem.

  9. SOME OF THE BEST MAINTENANCE PRACTICES FOR MANUFACTURING PLANTS

  10. Downtime Tracking is a Must EquipmentDowntime Trackingplaysapivotal roleinavertingunplanned downtimeevents. Itcan helpinforecastingthe needforrepairand maintenanceinany machineryinadvance.

  11. Realize the Importance of OEE DowntimeandOEEare inverselyproportional. The highertheOverall EquipmentEfficiency (OEE) percentageisthe lowerthedowntimewill be. Itisimportantthat plantsstartworking towardsachievinga greaterOEE.

  12. Regular Maintenance Operatorscanbringdown unplannedmanufacturing downtimebydoingregular machinemaintenance. theymustkeepinmind thatevenoilingand greasinglapsescanleadto bigmechanicalfailures. Maintenance managementisavery importantactivity.

  13. Train and Retrain the Machine Operators Untrainedoperatorsarea liability. Theyaremore likelytohandlethe machinesimproperly. Generally, themachines areupgradedregular intervalstoboost production. Yet, little emphasisispaidon trainingorretrainingthe operators. Itshouldbe givenequalimportance.

  14. Plan and Distribute Standard Operating Procedures Differentoperatorswork onthesamemachinesin shifts. Iftheiroperating proceduresdifferthenit canleadtovarious technicalissues. Putin placestandardoperating proceduressothat machinescanworkideally.

  15. Ensure that the Workplace is Clean and Organized Cleanmachinesand organizedwork environmentpromote safety. Theyalsomake detectionofminorfaults likeleakageofoil, spotting ofloosenutsandbolts easy. Operatorsmust ensurecleanlinessof workplaceandmachines atalltimes.

  16. Important Tools Must have a Designated Place Intheunfortunateeventof minormechanicalfailures, findingtherighttoolscan gettrickyattimes. This maycausepanic, confusion anddelay. Theoperators mustalwayskeepthe requiredtoolsattheir designatedplaces. This makestheiruseeasywhen needed.

  17. Routine Spares Must be Available Keepingallthesparesin advanceisnotpossiblefor anymanufacturingunit. Yet, therearesomewhich comeinuseatregular intervals. Consumable partsorthespares requiringchangemore oftenmustalwaysbe presentinstock. Thiswill helpinminimizingthe downtime.

  18. Give Planned Downtime its Due Credit Increaseddemandcanat timesputunduepressure ontheproductionunits. Thismaymeancontinuous work. But, eveninsuch circumstances, theplanned downtimeholdsits importanceinthesame amount. Planneddowntime andmaintenancework ensuresthattheunit doesn’thavetofacebigger mechanicalfailures. It shouldneverbepostponed inanycircumstance.

  19. Encourage the Operators to Become More Accountable Amanufacturingunitcannotworkwithgoodefficiency tilltheoperatorsstartowningtheirmachines. Theymust treatthemastheirresponsibility. Astickandcarrot approachformakingthemmoreresponsiblecanproveto beveryhelpful. Whentheyknowthatthey'llgetrewarded forhigheruptimeandreprimandedfordowntimethey'll takemoreinitiative. https://www.downtimecollectionsolutions.com

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