Predictive Maintenance Suggestions

[QA-Talport]

I need some help with Predictive Maintenance. In our last TS audit we were sited for not having a predictive maintenance program. The auditor told us what were doing was tool changing.
We are a automotive wiring harness provider. We have Komax cutting machines, compressors, presses for terminating, manual cutting machines and all of our boards are stationary.
We are at a lose in what to implement for predictive maintenance. Does anybody have any suggestions. Thanks.

Edit: Just to let you know, our plant is in Mexico and I really don't know what services are available where we are.

 

[Miner]

Re: Suggestions for Predictive maintenance

Some examples of predictive maintenance are thermal imaging to detect mechanical or electrical components that are running hotter than normal; analysis of fluids (hydraulic) for chemical breakdown, metal fines, contamination; vibration or acoustic analysis (bearings, alignment of rotating equipment, etc.).

There are other techniques.

 

[QA-Talport]

Re: Suggestions for Predictive maintenance

Some examples of predictive maintenance are thermal imaging to detect mechanical or electrical components that are running hotter than normal; analysis of fluids (hydraulic) for chemical breakdown, metal fines, contamination; vibration or acoustic analysis (bearings, alignment of rotating equipment, etc.).

There are other techniques.

What are the other techniques. The three you listed are the only three that we hear about and it is really not cost effective based on the equipment that we have. We do not have rotating equipment, we don't have hydraulic fluids and very little mechanical equipment.

 

[Jen Kirley]

Re: Suggestions for Predictive maintenance

We have Komax cutting machines, compressors, presses for terminating, manual cutting machines

QA-Talport, the question to ask is: which functions of these machines affects quality?

Planning for preventive maintenance is planning for realiable and continual good output for the tool's availability as well as ability to produce good product.

Thus, the questions to ask for planning are:

1. Which functions would affect readiness--that is, which would cause down time if the machine breaks and is not available?
2. Which functions would affect ability to produce good product if wear, misalignment, malfunction due to mechanical problems etc. occurs? This requires understanding of what machine aspect impacts what quality aspect.

An FMEA should help you with this planning process.

 

[RoxaneB]

Re: Suggestions for Predictive maintenance

If the technological aspects to Predictive Maintenance aren't feasible, what about the people aspects? Have you introduced a Routine Equipment Care program for your operators to follow, so that Maintenance personnel can do maintenance? This initiative helps the operator to understand his/her equipement and its use, plus improves communication between Operations and Maintenance.

If done properly, the number and length of interruptions may be reduced, as well as the number of equipment emergencies.

Have you also established Key Performance Indicators to track equipment performance, utilizations, delays, etc.? Highlighting problem areas (i.e., trends) will assist you in developing a more proactive maintenance program instead of reactive.

 

[QA-Talport]

Re: Suggestions for Predictive maintenance

This is great information for preventive maintenance, but I am really looking for some predictive maintenance ideas.

 

[Jen Kirley]

Re: Suggestions for Predictive Maintenance

Predictive and preventive are similar in that both are meant to prevent disruptions.

Predictive could be thought of as a guess as to when failure would happen, and do a repair before then. Wear, vibration and other trends would be examined.

Preventive would be more routine, like changing belts, filters and oil, and cleaning.

Read more about predictive maintenance here:
http://www.idcon.com/article-maintenancetwoeight.htm
http://www.plantservices.com/articles/2005/479.html
http://www.allbusiness.com/marketing-advertising/marketing-collateral/217498-1.html
...and also here.

 

[RoxaneB]

Re: Suggestions for Predictive Maintenance

Links to similiar discussions where you might obtain some ideas can also be found by scrolling down to the bottom of this screen.

 

[Marc]

Re: Suggestions for Predictive Maintenance

Predictive and preventive are similar in that both are meant to prevent disruptions.

Predictive could be thought of as a guess as to when failure would happen, and do a repair before then. Wear, vibration and other trends would be examined.

Preventive would be more routine, like changing belts, filters and oil, and cleaning.

A couple of existing threads to gum up the works:

Distinction between Preventive Maintenance and Predictive Maintenance
Predictive maintenance vs Preventive maintenance
Preventive vs. Predictive Maintenance - What is the difference? TS 16949 - 7.5.1.4

 

[Jrich]

Most items we use are Preventive. With respect to the predictive maintenance I agree with Miner. We use the vibration and thermal imaging of electrical panels and disconnect boxes. Thermal imaging is very good at detecting potential fire hazards and therefore potential downtime and operational disruptions.

You could probably ask your auditor what type of predictive items they have seen as well to get an idea of what else is out there.

The thermal testing works well, we generally find items each year based on this function. Vibration testing has not been as beneficial to us.

Good luck.
Jason.