Maintenance - types of work performed between scheduled and unscheduled repairs of production equipment. The goal is a guarantee of reliable and continuous operation. Timely maintenance and proper operation significantly reduce repair costs and forced downtime.
Maintenance Tasks
It is safe to say that maintenance is a decisive preventive action, which is absolutely necessary to ensure the continuous operation of production equipment and mechanisms in the intervals between scheduled repair operations. It involves the care and implementation of control over the operation of machines, their maintenance in good working order, routine inspection, cleaning, flushing, adjustment, purging and other equipment repairs.
Certain types of maintenance can be carried out directly on operating equipment using breaks and weekends. If there are appropriate permissions in the instructions for the operation of mechanisms and equipment, their short-term disconnection from the mains to a complete stop is possible. In such cases, some simple, but not to interrupt the production and technological processes is allowed .
Regulatory documents
GOSTs governing the use of maintenance systems and equipment repairs are 18322-78 "Equipment maintenance and repair system. Terms and definitions" and 28.001-83 "Equipment maintenance and repair system. Basic provisions". It is these standards that determine the classification and types of maintenance of electrical equipment.
Classification of Maintenance Types
At the stages of operation, repair and maintenance are divided into:
- Then storage.
- THEN when moving.
- THAT during operation.
- THEN while waiting.
By frequency:
- Periodic maintenance.
- Seasonal maintenance.
According to the operating conditions:
- MOT in special conditions.
According to the regulation of implementation:
- Regulated service.
- Periodic monitoring.
- Constant control.
- Streaming service.
- Centralized service.
- Decentralized service.
On the organization of execution:
- THEN operating personnel.
- THEN by specialized personnel.
- THEN operating organization.
- THEN a specialized organization.
- THAT by the manufacturer.
According to maintenance methods:
- Stream method of maintenance.
- Centralized maintenance method.
- Decentralized maintenance method.
According to the executive organization:
- operational staff
- specialized staff
- operating organization
- specialized organization
- by the manufacturer.
Separation of the concepts of "current" and "planned" service
In order to avoid the problem that is problematic for plant mechanics about exactly who should perform maintenance of industrial machines and mechanisms, it is customary to separate the concepts of “current” and “planned” maintenance. To some extent, it includes constant monitoring of equipment, with or without a short stop. And on the other hand, various types of maintenance are included in the maintenance and repair system or preventive maintenance repair as an element of the plan or as intermediate measures.
Routine maintenance
Various types of routine maintenance are carried out by the own production personnel of the site or workshop and include hourly and shift monitoring of equipment operation, inspection, lubrication, etc. From the point of view of the number of staff units, this is reasonable and rational, since an increase in the number of repair service workers is not required. On the other hand, this method allows existing operators to expand knowledge of the principles of operation and the technical structure of industrial equipment.
As a rule, the current maintenance of equipment is not regulated and involves:
- clear implementation of all operating rules, which are stipulated by the technical documentation of the manufacturer;
- regulation of a certain operating mode of equipment and prevention of overloads;
- compliance with the temperature regime;
- strict lubrication intervals in places where technical documentation requires it ;
- control of the state of deterioration of mechanisms and components during visual inspection;
- instant shutdown of electrical equipment in an emergency.
Scheduled maintenance
Scheduled maintenance and necessary repairs are carried out by qualified, specially trained repair team personnel. As a rule, scheduled works are more voluminous than routine maintenance, and may include dismantling entire units of machines and mechanisms. That is why competent mechanics are required.
Scheduled repairs and maintenance are regulated activities. It includes:
- checking the performance of equipment;
- adjustment and regulation of basic characteristics;
- cleaning of clogged working parts of equipment and mechanisms;
- replacement of filters and oil;
- identification of violations and malfunctions of equipment.
Data on changes in the operation of serviced mechanisms during maintenance is mandatory recorded: in inspection cards, repair logs, in a computer database, etc.
Technological maintenance cards, lubricant changes, specifications for material consumption, when scheduled or routine maintenance are very well established. With their help, repair technicians easily learn information about the frequency and list of necessary work.
Since certain types of maintenance and repair do not have a standard manual, the main documents are developed as part of a separate system. Moreover, for a certain type of industrial equipment requires its own list of works. For maximum convenience, the equipment of the enterprise is divided into groups to facilitate the development of maintenance methods for them.
Conditional equipment sharing
The first separation is carried out in accordance with the general status of the equipment as part of the main equipment of the enterprise:
- technological;
- electrical engineering;
- hoisting and transport, etc.
Further, numerous technological equipment of the enterprise, which is of the greatest interest for the repair team, is divided into subgroups:
- metal cutting equipment;
- forging equipment;
- foundry equipment;
- woodworking equipment, etc.
Inside the listed types of equipment it is much easier to allocate objects for characterization and implementation of repair work, as well as certain types of maintenance.
Scope of work by equipment groups
The list of works for metal cutting machines includes:
- assessment of wear of rubbing parts;
- tightening of fastening and tensioning elements;
- inspection of guards and clamps;
- determination of noise and vibration;
- regulation of the supply of coolants and oils, etc.
Some items are included in the list of maintenance for forging, woodworking, foundry equipment, with the exception of the specific features of operation and device.
Maintenance and Repair System
The main task of automated systems, according to which various types of maintenance are carried out, is to reduce costs under this budget item of the enterprise and significantly increase the reliability class of machines and mechanisms, which helps to reduce the cost of production and, consequently, increase revenue.
In the case of repairs, the task changes, since it is necessary to minimize not only the loss, but also the frequency of the work itself (regardless of type and volume). The ideal scheme that enterprises strive for is a complete rejection of emergency repairs, which inevitably lead to unscheduled production shutdowns.
In addition, operation and maintenance, in particular, repair work, are carried out in conditions of some uncertainty. Even the monitoring of depreciation of industrial equipment and many years of experience can not determine the specific volume and indicate the range of new spare parts for equipment. But the conveyor system assumes an accurate distribution of the necessary parts that may be required from the warehouse to a specific order.
What is a maintenance and repair system
The system of maintenance and repair is a complex of interconnected specialists, technical devices, reporting and fixing documentation results. All of them are necessary to maintain the proper condition of industrial equipment defined by GOSTs.
All enterprises in the country use a single concept of maintaining working machines and mechanisms in a state of continuous operability, part of which is the use of a legally approved system of preventive maintenance (PPR).
This system is a full-fledged set of organizational and technical actions carried out as planned, aimed at monitoring and ensuring the working condition of the machines and mechanisms available on the balance sheet of the enterprise. Such a system is used throughout the entire life of the equipment, subject to the operating conditions and conditions specified by the manufacturer. The exact fulfillment of all requirements, recommendations and operating instructions is mandatory.
The system of preventive maintenance work is based on the implementation of scheduled periodic inspections, monitoring the status of the main equipment and is in the nature of a preventive measure. Thus, a set of measures guaranteeing the maintenance of excellent operability of machines and mechanisms is carried out according to the developed monthly and annual schedules. The latter are compiled with the expectation of inadmissibility and the prevention of unexpected failure of industrial equipment, that is, with the expectation of reducing additional costs.
Maintenance system maintenance
The introduction of scheduled preventive repairs into production is ensured by:
- sufficient material and technical base and maintaining a certain frequency of repair work, deadlines;
- the full scope of the list of maintenance operations that guarantee uninterrupted operation of machinery and equipment;
- as soon as possible the period of stay of failed equipment in repair (especially capital).
Implementation of work
Depending on the category and technological importance of the equipment, as well as the stability of the processes and the safety of workers, certain types of repair work can be carried out as a repair due to a faulty technical condition, a regulated (planned) repair, a repair according to the worked out period, or a combination thereof.
Repair of industrial equipment is permissible to be carried out by the owners who directly use it, as well as by specialized teams of manufacturers or repair enterprises. The priorities of these organizational schemes for each plant are arranged depending on the availability of own reserves, equipment, qualifications of repair personnel and financial viability. But each industrial enterprise may, at its discretion, give preference to any method and form of PPR that is most consistent with the main areas of production.
MOT dates
Types and terms of maintenance are calculated in days or months, and this depends on the complexity and type of industrial equipment. So, for example, calculations for traction rolling stock (diesel locomotives, electric locomotives, etc.) are made according to the average values of the overhaul runs.
The frequency, types and terms of maintenance are calculated according to the calendar operating time and take into account the technical conditions of manufacturers.
Thus, as a result of a small analysis of the nature, classification, types of maintenance of industrial, production and technological equipment, we can conclude that it is necessary, systematic, and mandatory strict control. It is the combination of these components that will allow enterprises to achieve uninterrupted operation of machines and mechanisms, which, in turn, helps to save the budget, increase labor productivity and generate additional profit.