Industrial Maintenance Solutions

Knowledge of effective troubleshooting practices can go a long way toward getting equipment back on line quickly. Unfortunately, due to many reasons troubleshooting occupies too much of a technician's time. You might consider these six key elements to improve your troubleshooting skills: Understand the system Understand the problem and history Eliminate the obvious Develop possible causes and theories Eliminate causes, start with what is easy, or likely Validate and document the solution Firstly, if you do not understand the system and how it functions, you will be thrashing around in the dark. I found the best time to understand was while the equipment was running and producing product. Time spent studying the process while the equipment was running paid huge benefits when issues arose. It was always beneficial to listen closely to what the operator saw, heard, noticed, and did, just before the problem occurred. I learned quickly that a good operator was a great asset.

An effective maintenance system includes the following elements: Maintenance Policy Control of materials Preventive Maintenance Condition Monitoring Work Order Job planning Priority and backlog control Data recording system Performance measurement measures or indices Maintenance performance for a plant or an organization can be assessed through analysis of Reliability, Availability and Maintainability (RAM) plant data. Relevant parameters, measures or indices for specific plants can be identified. The performance over a period of time will show if it is improving, going down or being sustained. This will also help in knowing how well the objectives are being met. In addition, it will guide the areas which are strong and which need to be strengthened. Use of computers and dedicated software will certainly help in implementing this and the maintenance management system in general.

Following are the major functions of a maintenance department • Maintenance of installed equipment and facilities • Installations of new equipment and facilities • PM tasks – Inspection and lubrication of existing equipment • CM tasks – monitoring of faults and failures using appropriate techniques • Modifications of already installed equipment and facilities • Management of inventory • Supervision of manpower • Keeping records

A maintenance strategy or option means a scheme for maintenance, i.e. an elaborate and systematic plan of maintenance action. Following are the maintenance strategies that are commonly applied in the plants. • Breakdown Maintenance or Operate to Failure or Unplanned Maintenance • Preventive or Scheduled Maintenance • Predictive or Condition Based Maintenance • Opportunity Maintenance • Design out Maintenance

The term ‘maintenance’ means to keep the equipment in operational condition or repair it to its operational mode. Main objective of the maintenance is to have increased availability of production systems, with increased safety and optimized cost.

New research Quite apart from greater expectations, new research is changing many of our most basic beliefs about age and failure. In particular, it is apparent that there is less and less connection between the operating age of most assets and how likely they are to fail. Figure 1.2 shows how the earliest view of failure was simply that as things got older, they were more likely to fail. A growing awareness of 'infant mortality' led to widespread Second Generation belief in the "bathtub" curve.

Replacing bearings can prove to be expensive, both in new bearing cost and lost productivity. Some manufacturer takes bearings and expertly remanufactures them to like-new condition for extended service.

Reduce downtime with remanufactured bearings Paying attention to these details during regular maintenance checks can help you determine if a bearing needs maintenance before it causes unnecessary downtime and expense. Careful observation is the first step to creating a program that monitors your bearings and surround operations.

Since the 1930's, the evolution of maintenance can be traced through three generations. RCM is rapidly becoming a cornerstone of the Third Generation, but this generation can only be viewed in perspective in the light of the First and Second Generations. The First Generation The First Generation covers the period up to World War II. In those days industry was not very highly mechanized, so downtime did not matter much. This meant that the prevention of equipment failure was not a very high priority in the minds of most managers. At the same time, most equipment was simple and much of it was over-designed. This made it reliable and easy to repair. As a result, there was no need for systematic maintenance of any sort beyond simple cleaning, servicing and lubrication routines. The need for skills was also lower than it is today.

Maintenance has changed Over the last twenty years, maintenance has changed, perhaps more so than any other management discipline. The changes are due to a huge increase in the number and variety of physical assets (plant, equipment and buildings) that must be maintained throughout the world, more complex designs, new maintenance techniques and changing views on maintenance organization and responsibilities.

We specialize in providing maintenance consulting and maintenance management services, with a focus on industrial maintenance fields such as Oil and Gas, Power, and Chemicals. Our team of maintenance consultants consists of experienced professionals who are dedicated to implementing and improving preventive maintenance management programs, reducing equipment downtime, cutting maintenance costs, and preventing maintenance emergencies. We also offer solutions to motivate employees, increase productivity, and improve inventory and purchasing processes. At our company, we understand the urgency of maintenance issues in the industrial sector. That's why we are committed to providing urgent solutions and innovative approaches to solve the most complex maintenance challenges. We believe our expertise and passion for maintenance solutions, coupled with our commitment to customer satisfaction, make us the ideal partner for businesses seeking to improve their maintenance management systems.