& iquestQue Proactivo is?
Look at Mr. Gerardo's article Trujillo that stops my pleasure, he/she doesn't have waste.
At the present time the cost of operating a team until this it fails (Reactive Maintenance), it is very high in terms of unproductive time, you leave of reserve, manpower and cost of the repair. The techniques of Preventive maintenance are based on the change or substitution of parts in function of an interval of time and in most of the times the pieces are moved away when they still have capacity to continue working & ndash According to Forbes Magazine; & ldquoUn 33% of the preventive maintenance activities is desperdiciadas&rdquo. The techniques of Maintenance Predictivo, indicates us the moment in the one that the piece or component is next to the flaw, but he/she doesn't tell us as avoiding it. - Fortunately, a new well-known alternative exists as & ldquoMantenimiento Proactivo&rdquo.
The Maintenance Proactivo, is a maintenance philosophy, directed fundamentally to the detection and correction of the causes that generate the waste and that they drive to the flaw of the machinery. Once the causes that generate the waste have been located, we should not allow that these continue present in the machinery, since of making it, their life and acting, they will be reduced. The longevity of the components of the system depends that the parameters of flaw causes are maintained inside acceptable limits, using a practice of & ldquodetección and corrección&rdquo of the deviations according to the program of Maintenance Proactivo. Acceptable limits, it means that the parameters of flaw causes are inside the range of operational severity that will lead to an acceptable life of the component in service.
In mechanical systems operated under the protection of liquid lubricants, to control five flaw causes fully grateful, it can take to the continuation of the life of the components in many occasions until of 10 times with regard to the current operation conditions. These five critical causes to control are:
- Particles
- It dilutes
- Temperature
- Air
- Fuel
- Chemical compounds
Any deviation of the parameters of the previous flaw causes, he/she will give deterioration of the material of the component as a result, followed by a drop in the acting of the team and concluding with the write-off of the components or the functionality of the team.
The conditions of use of the teams that lead to flaws (conditional of flaw), they produce material deterioration (it fails incipient) that is the direct cause of the loss in the acting of the team (it fails operational) and that finally it is in the lack of functionality of the team (it fails catastrophic)
To be able to detect and to correct the flaw causes, control methods and pursuit that allow us to identify their level and behavior should settle down.
In the daily activity of the maintenance, it is common to meet with conditions of & ldquoconvivencia&rdquo with the problems instead of using a real technique of detection and solution of the flaw causes.
Let us see the following example: A new team arrives to our plant and immediately, the preventive maintenance routines that settle down in the maker's manual settle down. 500 hours after the team is put in operation, one of the baleros main flaw, stopping the operation of the team. Maintenance receives the immediate pressure of Production and immediately it is to locate the spare part. & ldquoDos weeks of time of entrega” - more pressure of Production - the piece finally arrives and it is changed. Last 500 hours, the balero fails again, the delivery of the piece decreases to a couple of days; Maintenance gives the instruction of buying two additional baleros for warehouse. Resolved problem from now on: the maintenance program establishes the baleros change at the 450 hours.
The Maintenance Proactivo uses specialized techniques for monitorear the condition of the teams being based fundamentally on the analysis of oil to establish the control of the parameters of flaw cause.
Many of the most important companies in Mexico use programs of analysis of used oil at the moment to establish the condition of their teams and to make decisions of Preventive maintenance (to change the oil) or of Maintenance Corrective (to change the piece that is damaged). The analysis of oil is conceptualized as a tool for & ldquosalvar&rdquo teams and to determine when a piece is to fail, to program its repair before a catastrophic flaw.
The Maintenance Proactivo, establishes a technique of early detection, monitoreando the change in the tendency of the parameters considered as flaw cause, to take stocks that you/they allow to the team to return to the established conditions that allow him to act appropriately for but time.
Is the analysis of oils traditionally known like a technique of the Maintenance Predictivo, since allows us to predict the flaw of a component, however, do we wonder & what an iquestPor to wait to that the piece fails or does he/she appear us waste to take an action that allows him to extend its service life? When analyzing the results of waste of metals & ndash commonly reported in p.p.m. (parts per million) & ndash only takes an action when the results exceed the warning limits or established critics. The quantity of p.p.m. of iron that appears in the laboratory report, he/she will never return to the component, that is to say, the life of the component has been shortened.
Let us make a comparison between the Industrial Maintenance and the Maintenance of the human body: Who are operating in & ldquoservicio severo&rdquo (you travel, long shifts, pressures, stress, bad feeding, little exercise, etc.) we are in the face of the risk of a heart attack. In this case, the Maintenance corrective, would be the flaw of the heart, what would leave us useless, the Preventive maintenance would be an operation that installed us a by-pass or a pacemaker, the Maintenance Predictivo, it would be a complete analysis of blood, levels of cholesterol, etc. that indicated us the condition of our organism and the possibility of a heart attack. The technique of the Maintenance Proactivo would consist on a monitoring of those parameters and a & hábitos&rdquo ldquocambio that allow to decrease those factors that we know as the flaw cause; he/she implies making but exercise, eating less red meat, but vegetables, to organize our time, in short a new life. In the Industrial Maintenance that & hábitos&rdquo ldquocambio means largely modifying our form of seeing the lubricants, the particles, the water, the temperature, the fuel and the air. It means a fight against the invisible thing, the particles that more they affect to the components of rotational machinery, they are those in the range of the 10 microns (the human eye is able to see bigger particles to 40 microns), the water, the air and the fuel, they are difficult to detect at first sight and we are accustomed to cohabit with them.
It is necessary a radical change in the way of managing the lubricants and to perceive the cleaning of these, it is necessary to change our perception what means a good filtration and a good administration of the lubrication.
The Education (Training and training) it is a fundamental factor to take advantage of to the maximum the techniques of analysis of oils as:
& middot Count of particles
& middot Count of ferrous particles
& middot direct Ferrografía
& middot Analytic Ferrografía
& middot Viscosity
& middot Humidity
& Combustible middot / Prod. chemical
& middot Metals for espectroscopía
& Infrared middot for FTIR
& middot BN and AN
& middot Soot
Additionally, it is required of the structure of a program of Maintenance Proactivo, in which the critical teams settle down to those that this technology will be focused, to make an analysis in their flaw ways, consequences, symptoms and goods (well-known as FMECA for their initials in English) and to determine our control objectives for each one of them, the analysis types that will be made in routine base and for condition and the measures that will be taken (exclusion methods, and of filtration) to return the parameters to the established condition.
Our recompense will be then the obtaining of savings so significant as the obtained ones in great quantity of companies that have attached to these programs and that they can arrive to the amplification of the life of the components of up to 10 times and up to 6 times adult life of the lubricants. 
References:
Extending component service life through Proactive Maintenance.
Dr. E.C.Fitch - Tribolics Inc.
Oil Analysis and Proactive Maintenance Seminar
James C. Fitch. - Treadmill Corporation
Other performances
Beginning with the design of preventive maintenance plans and continuing with the execution of systematic of the maintenance predictivo. The elaboration of the plans of Maintenance is based besides in the Analysis of Risks and in the techniques of the Analysis of Reliability of the facilities.
The analysis of reliability consists of two fundamental parts:
- The information: where you recaban the data corresponding to the teams on those that he/she will carry out the analysis.
- The decision: where in essence they are to establish tasks of prevention (technically feasible and economically profitable) of the consequences in the failure ways.
In the phase of information the different functions are determined (main and secondary) of each element of the team that is analyzing in their operational context, later on are determined for each function the function shortcomings, that is to say the form in that one manifests the inability of the element to develop the corresponding function.
The following step is to determine the failure ways that are the shortcomings that we really appreciate in the team (the usually well-known thing as mishap), once fact this is necessary to determine the cause root of the failure on which we will study its solution.
With all these data he/she is carried out the evaluation of the consequences of each failure in each one of the scales (Operational, Security, environment and Cost) and it is located in the womb of risk in the corresponding place as they are the severity and the probability of the failure.
In the phase of decision, supported in the diagram of decision and in the curve P-F, is determined for each cause root the task of Maintenance to carry out, the frequency with which it will carry out, who will execute it, as well as the stock to maintain and the new resulting risk when applying this plan of Maintenance.
Leaves of decisions
Of the leaf of decision it is generated the plan of maintenance of prevention and the rediseños to carry out, as well as the decisions on having stock or not and the importance of the correction tasks that it is necessary to make after discovering something bad in the facilities, as consequence of the realization of the tasks of prevention. In the figure the approach is shown to determine the maintenance tasks Predictivo that are the first ones that are to settle down (diagram P-F). The interval P-F, is the time of which prepares since the mishap is detected, until the system stops to work. In this interval we will have to carry out the maintenance of the team.
They are selected (in the first place) the tasks corresponding to the area TO to improve their mantenibilidad and, therefore, to reduce the costs associated to them. For they are used it the mantenibilidad approaches and the techniques Read Manufacturing (Poka Yoke and SMED), together with the approaches contributed by the Value analysis
The basic process of application has as objectives to reduce the costs and to increase the effectiveness of the teams. For they are divided it the tasks in:
- With added value. They are those for which the client is willing to pay. In turn they are divided in:
or External: They can be carried out with the team in march.
or you Intern: One must carry out unavoidably with the stopped team.
- Worthless added. They are all those that would not influence about the value of the product or service in the event of not being made. In turn they are divided in:
or Necessary. Today per today they are necessary, although they don't add value to the product or service, due to the means that we usually prepare. For example, the transports of elements don't add value, but he/she can that today per today they are necessary, since we don't have another system to put them in their place.
In turn they are divided in:
or External: Those that can be carried out with the team in march.
or you Intern: Those that for force one must carry out with the stopped team.
or Unnecessary. Not to make them doesn't influence for anything in the product or service and yes it would represent a decrease of costs.
The price of a product or service can be expressed by the following equation:
I price = Margin + Cost
In turn, the cost is formed by the following concepts:
Cost = Added Value + Waste
The methodology of Improvement of the Mantenibilidad seeks:
- To classify the operations in "with added value" and "worthless added."
- The operations "worthless added" to classify them in necessary and unnecessary.
- To eliminate all the unnecessary operations that we can (With that which, we are diminishing costs and increasing the effectiveness).
- To transform in external all the operations "worthless added" you intern that can (with that which we increase the effectiveness).
- To transform in external all the operations "with added value" you intern that can (with that which we increase the effectiveness).
- To reduce to the maximum the resources (time and costs) of the internal operations (with that which we are reducing costs, increasing the effectiveness and reducing the added value).
- To reduce the external operations (with that which we reduce costs).
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