How to Reduce Unplanned Downtime: 8 Critical Maintenance Considerations
The starting point of reducing the unplanned posture is not to do more care, where and why loss occurs. The downtime can be directed to the most critical losses of maintenance resources when the incident frequency, repair time and production effect is measured separately.
1-2: Defending dictionary and criticality
Identify common posture codes among teams first; separate large headers such as 'mechanical failure' to action such as sensor, bearing, feeding, bonding or cleaning. Then criticize equipment according to safety, quality, capacity, redundancy and delivery effect. The source is waste to give the same care intensity to each asset.
3-4: Proper care plugs and basic conditions
If the wear may be predicted, periodic; if there is a status indicator, cutover; quick changeable and low risk, controlled failure after maintenance can be selected. Basic conditions such as cleaning, tightness, alignment, lubrication and calibration do not produce advanced sensor investment permanently without being secured.
5-6: Spare parts and standard work
Critical backups should be classified with the possibility of failure, delivery time and stock cost. Installation procedure, torque, lubrication quantity and commissioning control should also be standardized until the correct part is available. It reduces the repair time to update the photos post-task cards and those learned after failure.
7-8: Competence and root cause cycle
It should be provided that operators report abnormal audio, temperature, leakage and pattern change early. Five reasons for repeating or high-impact postures, the root cause is done by error tree or similar method; the effect of action is verified by the next data. KPI should also contain MTBF, MTTR and repeat rate not only total downtime.
Application control list
- Make rinsing codes in action.
- Create equipment critical matrix.
- Select proper care plugs for each fault mode.
- Update Critical backup and standard business list.
- Confirm after action in repeating failures.
Conclusion
Planless posture, not with a single maintenance project; data, basic equipment conditions, accurate backup, standard work and learning cycle gradually decreases.
Manstechnic approach
Manstechnic determines the areas of improvement by linking the process data of repeating losses in bonding and lubrication points.