Maintenance - types of work performed in the interval between scheduled and unscheduled repairs of production equipment. The goal is to guarantee reliable and continuous operation. Timely maintenance and competent operation significantly reduce repair costs and downtime.
Maintenance tasks
It's safe to say that maintenance is a critical preventive action that is essential to keep production equipment and machinery running smoothly between scheduled maintenance. It involves the maintenance and control of the operation of machines, their maintenance in good working order, scheduled maintenance, cleaning, flushing, adjusting, purging and other repairs of equipment.
Certain types of maintenance can be carried out directly on the operatingequipment using breaks and days off. If there are appropriate permits in the operating instructions for mechanisms and equipment, it is possible to briefly disconnect them from the power grid until they stop completely. In such cases, some downtime is allowed, but so that the production and technological processes are not interrupted.
Regulatory documents
GOSTs regulating the use of maintenance systems and equipment repair are 18322-78 "Maintenance and repair system of equipment. Terms and definitions" and 28.001-83 "System of maintenance and repair of equipment. Basic provisions". It is these standards that determine the classification and types of maintenance of electrical equipment.
Classification of types of maintenance
According to the stages of operation, repair and maintenance are divided into:
- STORAGE MOT.
- TO when moving.
- Maintenance during operation.
- TO while waiting.
By frequency:
- Periodic maintenance.
- Seasonal maintenance.
According to operating conditions:
TO under special conditions
According to the regulation of execution:
- Regulated service.
- Periodic control.
- Constant control.
- Inline service.
- Centralized service.
- Decentralized service.
According to the organization of execution:
- Maintenance by maintenance personnel.
- MAINTAINED by specialized personnel.
- Maintenance by the operating organization.
- TO by a specialized organization.
- MAINTAINED FACTORY.
By maintenance methods:
- Flow method TO.
- Centralized TO method.
- Decentralized TO method.
By executive organization:
- operating staff,
- specialized personnel,
- operating organization,
- a specialized organization,
- manufacturer.
Separation of the concepts of "current" and "scheduled" maintenance
To avoid the problematic issue for the mechanics of enterprises of who exactly should perform the maintenance of industrial machines and mechanisms, it is customary to separate the concepts of "current" and "scheduled" maintenance. To some extent, it includes constant monitoring of the equipment, with or without short-term shutdown. And on the other hand, various types of maintenance are included in the maintenance and repair system or scheduled preventive maintenance of the preventive maintenance program as an element of the plan or as intermediate measures.
Ongoing maintenance
Various types of routine maintenance are carried out by the production staff of the site or workshop and include hourly and shift control of equipment operation, inspection, lubrication, etc. From the point of view of the number of staff positions, this is reasonable and rational, since notan increase in the number of maintenance workers is required. On the other hand, this method allows existing operators to increase their knowledge of the principles of operation and the technical design of industrial equipment.
As a rule, the current equipment maintenance is not regulated and assumes:
- clear execution of all operating rules that are specified in the technical documentation of the manufacturer;
- regulation of a certain mode of equipment operation and avoidance of overloads;
- compliance with the temperature regime;
- strict lubrication intervals where required by technical documentation;
- monitoring the state of deterioration of mechanisms and assemblies during visual inspection;
- momentary shutdown of electrical equipment in case of emergency.
Scheduled maintenance
Scheduled maintenance and necessary repairs are carried out by qualified, specially trained personnel of the repair team. As a rule, scheduled work is more voluminous than current maintenance, and may include dismantling of entire machine assemblies and mechanisms. That is why competent mechanical specialists are required.
Scheduled repairs and maintenance are a regulated type of work. It includes:
- Checking equipment performance;
- adjustment and regulation of the main characteristics;
- cleaning clogged working parts of equipment and mechanisms;
- change filters and oil;
- revealingviolations and equipment failure.
Data on changes in the operation of serviced mechanisms during maintenance are mandatory recorded: in inspection cards, repair logs, in a computer database, etc.
Very well proven maintenance checklists, lubricant changes, material consumption specifications when scheduled or routine maintenance is carried out. With their help, repair specialists 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 within a separate system. Moreover, a certain type of industrial equipment requires its own list of works. For maximum convenience, plant equipment is divided into groups to facilitate the development of maintenance methods for them.
Conditional separation of equipment
The first division is carried out in accordance with the general status of the equipment as part of the main equipment of the enterprise:
- technological;
- electrotechnical;
- lifting and transport, etc.
Next, the numerous technological equipment of the enterprise, which is of the greatest interest to the repair team, is divided into subgroups:
- metal cutting equipment;
- forging equipment;
- casting equipment;
- woodworking machinery, etc.
Insideof the listed types of equipment it is much easier to select objects for the characteristics and implementation of repair work, as well as certain types of maintenance.
Scope of work by equipment groups
The list of work for machine tools includes:
- assessment of wear of rubbing parts;
- tightening fasteners and tension elements;
- checking guards and clips;
- determination of noise and vibration;
- regulation of the supply of coolants and oils, etc.
Some items are also included in the maintenance list for forging, woodworking, foundry equipment, except for the specific operation and device.
Maintenance and repair system
The main task of automated systems for which various types of maintenance are carried out is to reduce costs for this item of the enterprise budget and significantly increase the reliability class of machines and mechanisms, which helps to reduce the cost of production and, accordingly, increase income.
In the case of repairs, the task changes, since it is necessary to minimize not only losses, 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, is carried out inconditions of some uncertainty. Even the monitoring of the wear of industrial equipment and many years of experience cannot determine the specific volume and indicate the range of new spare parts for equipment. But the conveyor system involves the exact distribution of the necessary parts that may be required from the warehouse for a specific order.
What is the maintenance and repair system
The maintenance and repair system is a complex of interconnected specialists, technical devices, reporting and fixing the results of documentation. All of them are necessary to maintain the proper condition of industrial equipment, as defined by GOSTs.
All enterprises in the country use a unified concept of keeping working machines and mechanisms in a state of continuous operation, part of which is the use of a legally approved preventive maintenance system (PPR).
This system is a full-fledged set of organizational and technical actions carried out in a planned mode, 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 during the entire period of operation of the equipment, subject to the regime and operating conditions specified by the manufacturer. Accurate compliance with all requirements, recommendations and operating instructions is mandatory.
The preventive maintenance system is based on the implementation of plannedperiodic inspections, control of the condition of the main equipment and is in the nature of a preventive measure. Thus, a set of measures that guarantee the maintenance of excellent performance 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 prevention of unexpected failure of industrial equipment, that is, in the expectation of reducing additional costs.
Providing the MRO system
Introduction of the preventive maintenance system into production is ensured by:
- sufficient material and technical base and maintaining a certain frequency of repair work, deadlines;
- a complete list of maintenance operations carried out to ensure the uninterrupted operation of machinery and equipment;
- the shortest possible time for failed equipment to be repaired (especially capital).
Work in progress
Depending on the category and technological importance of the equipment, as well as the stability of the processes produced and the safety of workers, certain types of repair work can be carried out as a repair due to a faulty technical condition, regulated (scheduled) repair, repair according to the established deadline or their combinations.
Repair of industrial equipment is permissible to be carried out by the enterprises-owners who directly use it, as well as by specialized teams of manufacturing plants or repair enterprises. Theseorganizational charts for each plant are arranged depending on the availability of their own reserves, equipment, qualifications of maintenance personnel and financial solvency. But each industrial enterprise may, at its own discretion, give preference to any method and form of PPR that best suits the main areas of production.
Terms of maintenance
Types and terms of maintenance are calculated in days or months, and it 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 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 essence, 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 receive additional profit.
