您是否曾经在许多“ 10分钟”或“快速”的机油换地点停下来?如果是这样,您已经听到并看到那里的服务技术人员执行了“精确维护”的良好基本示例。

在您的汽车上方和下方,他们在一个非常确定的程序清单上工作 - 打开引擎盖,检查流体水平并取下液位,打开油底锅螺栓以排干旧的油,卸下旧的机油滤清器。。。等等。然后,他们安装新的过滤器,重新安装油底壳螺栓,放入正确量的油,不久之后,您就在路上。

该过程非常脚本,几乎是自动的,并且每个步骤都得到了传达和认可。该过程背后的想法是,每个技术人员都“按本书进行”,并以相同,可预测的方式进行每一个油的每一步,都比每个客户都能获得相同的成功结果。

为什么需要精确维护?

好问题。那么,“精确维护”对于使用塑料处理机械的维护技术人员意味着什么?

简而言之,它描述了an approach where all of the maintenance actions that technicians perform are done in identical, precise, and repeatable ways, according to measurable, defined standards.

Precision维护首先是由需要最高水平的设备正常运行时间和可靠性(例如NASA或美国海军)开发的,此后已扩散到许多设备至关重要的组织。

Plastics processors need and benefit from precision maintenance because it can dramatically improve equipment reliability and uptime.

How does precision maintenance work?

The goal of precision maintenance is to enable maintenance technicians to “up their game”—and ultimately improve plastic processing equipment uptime—by routinely adhering to a defined set of maintenance specifications and measurements for all of their maintenance actions.

将其视为质量保证过程解释、促进和执行“最佳practices” on every job. When consistently used, precision maintenance eliminates maintenance “variances” that can cause equipment failure and downtime.

精确的典型要求/标准维护计划可能包括:

  • Using the correct tools, in proper working condition and calibrated to complete tasks precisely
  • 使用质量,规格替换零件
  • 确保所有组件的正确拟合和公差,扭矩和紧张局势
  • 确保在所有设备中都存在清洁,无污染物的润滑
  • Ensuring that all equipment has a low level of total machine vibration
  • 确保准确的轴对齐和旋转零件的精确平衡
  • Ensuring that proper equipment operating temperatures are maintained
  • 确保识别和消除失败的根本原因
  • 系统地定义和应用所有标准

对于维护专业人员而言,所有这些要求似乎很明显 - 也许是最后一个要求。正如它所说,精确维护取决于标准的系统定义和应用,并通过使用通用技术和测量来定义依从性和一致性。这是一个至关重要的点。

让我进一步解释。没有维护技术人员会说他或她不知道干净或脏润滑剂之间的区别,他们无法测量工作温度,或者他们不知道如何扭矩紧固件。但是,在没有确定的标准或完成工作的措施的情况下,人们将以不同的方式做同样的工作。

This is where defining your standards comes in. As soon as you can create standards, all of your technicians can begin doing things the same way. Because defining all of the requirements and standards you might need takes time, start with a couple of the more common ones, such as ensuring clean lubrication and maintaining proper operating temperatures to get the ball rolling.

塑料处理设备维护

从基础开始:培训维护人员

精确维护计划的另一个关键构件是基本维护技能和技术的个人培训,包括:

  • Assembly skills
  • 测量和调整扭矩
  • 测量振动
  • Providing proper and adequate lubrication
  • 确保在组装和正常工作温度下适当的拟合,对齐和平衡
  • 了解基本原理图
  • 故障排除技术和最佳实践

当然,如果您宣布这样的培训,您的一些维护同事和人员会说他们“知道”如何做这些事情。而且,如上所述,这始终是正确的。但是,一旦您开始进行,每个人都会发现“他们不知道自己不知道的东西”。

在那时,您的团队可能只会与您一起加入,以认识到设备,常见工具和测量方法的准确和当前知识的价值以及执行和完成任务的通用过程。您从基础开始,然后从那里工作。

确定高维护设备

To start a precision maintenance effort, I would recommend you begin with “low-hanging fruit.”

If your plant and equipment are typical, there are always a few pieces of equipment – or a particular type – that tends to fail more often or need more frequent work.

您可以采取以下三个步骤来确定设备的优先级,并开始为您的设施提供精确维护程序:

  1. Systematically evaluate, measure, and define key characteristics of the equipment and its problems.
  2. Use this information to put a plan together of the correct parts, tools, procedures, and standards.
  3. Then create a schedule by which you maintain, diagnose, and repair that equipment.

By following these three steps, you’re bound to identify issues you hadn’t considered. And then precision maintenance will begin to work for you, helping you restore that equipment to a level of performance you had not thought possible.

Checklists & Templates to Get Started

Conair免费提供downloadable routine maintenance checklists and detailed preventive maintenance templates,对于大多数类型的辅助设备,包括:

  • 搅拌器
  • 干衣机
  • Loaders
  • 温度控制单元
  • 泵罐

Conair还提供交钥匙维护计划,包括全面MachineHealth™设备评估- 处理器需要保持高正常运行时间和最佳生产所需的一切!

Download your free maintenance templates

Why-You-Need-Precision-Maintenance

Why You Need Precision Maintenance and How to Get Started

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