AU U L A LA 1 1 Introduction to maintenance economic globalization, the quest for total quality in services, products and en vironmental management has

become the goal of all businesses. - What maintenance has to do with the overall quality? Machine availability, increased competition , increased profitability, customer satisfaction, products with zero defects ... - I do not understand! Let's compare. Imagine that I am a manufacturer of beari ngs and has competitors. Well, so I will keep my clients and cultivate new ones, I need to get the most out of my machines to offer bearings with zero defects a nd competitive price. Should I also set a rigorous schedule of manufacture and d elivery of my bearings. Imagine you I do not maintain my machines ... - I'm begi nning to understand. If I have a good maintenance program, losses are inevitable , since machines with defective or broken will cause: · · · · · · Decrease or di scontinuation of production, delivery delays, financial losses, increased costs; bearings with possibilities of defective manufacturing; customer dissatisfactio n, loss of market. With To avoid the collapse of my business should obligatorily set a maintenance progr am with preventive methods in order to get bearings in the pre-set quantities an d quality must also quality. include in the program, the tools being used and th e estimates of the useful life of each element of the machines. All these aspect s show the importance to be given to maintenance. A brief history Maintenance, though unseen, has always existed, even in earliest times. Began to be known by the name of maintenance around the sixteenth century in central Eur ope, along with the rise of the mechanical clock, when the first technicians in installation and service. Took shape during the Industrial Revolution and establ ished itself as an absolute necessity in the Second World War. In the early post war reconstruction, England, Germany, Italy and Japan mainly underpinned its per formance in industrial engineering and maintenance bases. In recent years, with intense competition, the timing of delivery have become relevant to all companie s. With that came the motivation to guard against failures of machines and equip ment. This motivation led to preventive maintenance. In short, the past twenty y ears is that there has been concern of technicians and entrepreneurs to develop specific techniques to improve the complex system Human Machine / Human Service / Host / Service. CLASSROOM 1 Concept and objectives We can understand how to maintain the set of technical care required for the smo oth and continuous machinery, equipment, tools and facilities. These precautions involve the conservation conservation, adaptation, restoration, prevention. fit ness for restoration replacement and prevention, for example, when we keep the g ears lubricated, we are keeping them. If we are rectifying a table trowel, we ar e restoring it If we're changing the plug of an electrical cable, will be replac ing it. • From general, the maintenance at a company aims to: maintain equipme nt and machines capable of full operation to ensure normal production and produc t quality; prevent possible faults or breaks the elements of machines.

 

Achieving these goals requires daily maintenance services for routine and period ic repairs scheduled. Maintaining an ideal machine is one that enables high avai lability for production during the entire time she is in service and an appropri ate cost. Routine services and periodic services The services consist of routine inspection and verification of the technical uni ts of the machines. The detection and identification of small defects of the ele ments of the machines, checking the lubrication system and finding fault setting s are examples of services from routine maintenance. CLASSROOM 1 Responsibility for routine services is not only the maintenance people, but also for all machine operators. We stress that there is also an emergency or correct ive maintenance that will be looked straight ahead. The periodic maintenance ser vices consist of various procedures aimed at keeping the machinery and equipment in good working condition. These procedures involve several operations: check off monitor the machine parts subject to greater wear;€adjust or replace components in predetermined periods, examination of the components before the end of their warranties, reschedule, if necessary, the prevention program, test electrical co mponents etc.. The periodic maintenance services may be made during long stoppages of the machi nes for reasons of breakage of parts (which should be avoided) or other failures , or when planning new service, or even hourly in the change of shifts. The shut downs are aimed at the complete disassembly of the machine to take your parts an d assemblies. Damaged parts, after examination, are reconditioned or replaced. T hen, the engine is reassembled and tested to ensure the required quality in thei r performance. Unscheduled repairs also occur and are under the category known a s corrective maintenance For example, if a drill corrective. Bench is running an d the belt breaks, it should be replaced immediately so that the machine will no t stop. The monitoring and recording of machine state, as well as the repairs ar e important factors in any maintenance program. Types of maintenance There are two types of maintenance: planned and unplanned planned. The planned m aintenance is classified into four categories: preventive preventive, predictive and TPM Terotecnologia predictive Terotecnologia. Preventive maintenance is the set of procedures and anticipated actions that aim to keep the machine running. The predictive maintenance is a kind of preventive action based on knowledge of the conditions of each component of the machinery and equipment. These data are obtained by monitoring the wear of vital parts of sets of machinery and equipme nt. Periodic tests are performed to determine the proper time for replacement or repair parts. Examples: vibration analysis, monitoring of bearings. The TPM (to tal productive maintenance) was developed in Japan is a model rooted in the conc ept of "my machine, I'll take care." TPM will study in Lesson 2. The Terotecnologia English is a technique that determines the participation of a specialist from the maintenance equipment design to installation and the first hours of production. With terotecnologia, we obtain equipment to facilitate the intervention of the maintainers. Nowadays there are companies that implement the so-called retrofitting, which are reforms of equipment with updated technology. For example, to reform a conventional lathe turning it into CNC lathe is a case

       

 

of retrofitting. The unplanned maintenance is classified into two categories: c orrective and of occasion occasion. The corrective maintenance is designed to lo cate and repair defects in equipment that operate on a continuous work. Keeping time is to make repairs when the machine is stopped. CLASSROOM 1 Planning, scheduling and control In industrial facilities, the maintenance shutdowns are a constant concern for t he production schedule. If the stops are not provided, there are several problem s, such as schedule delays, manufacturing, machine downtime, increased costs etc .. To avoid these problems, companies have introduced, in administration, planni ng and scheduling of maintenance. In Brazil, planning and scheduling of maintena nce were introduced during the 60s. The function means knowing the work plan, th e resources to execute them and make decisions. The task scheduling means determ ining staff, day and hour for the work involved. A maintenance plan should answe r the following questions: - - - - - - How? What? How long? Who? When? How much? The first three questions are essential for planning and the last three, which a re essential for programming. The implementation plan must be monitored to obtai n information to guide decision making regarding equipment and maintenance teams . The control is done through the collection and tabulation of data, followed by interpretation. This is how we are established standards or working standards. CLASSROOM Organization and administration By organizing the maintenance service we can understand how they are composed, a re ordered and the services are structured to achieve the intended objectives. T he administration of maintenance service aims to regulate the activities, orderi ng the factors of production, contributing to the production and productivity ef ficiently, without waste and rework. The biggest risk that the maintenance can s uffer, especially in large companies, is the loss of its main objective, because , mainly,€the lack of organization and an excessively bureaucratic administratio n. 1 Exercises Exercise 1 Check V for true statements and F for false. a) () Conservation, rest oration and replacement of machine elements are unnecessary operations in the ma intenance programs of companies. b) () to ensure normal production and quality o f manufactured products is one of the goals of maintenance performed by business es. c) () The oil change service is a routine maintenance of machinery. d) () Th e responsibility for routine services, maintenance of machines, is exclusive of the operators. e) () The complete dismantling of a machine occurs only in emerge ncy situations. f) () The check adjustment is a routine service in the maintenan ce of machinery. g) () The record of the state of a machine and repairs made it part of the maintenance programs of companies. Exercise 2 Answer. a) As is preve ntive maintenance? b) What is the purpose of corrective maintenance? c) As is th e maintenance of time? d) in maintenance, which means planning? e) When it comes to maintenance, which are the basic questions that must be made in the planning phase? And in the programming phase? Exercise 3 Complete the sentences. a) A go od maintenance program must be based on the organization and ................... ................. .................................................. ........... ............................ b) The collection and tabulation of data followed b y interpretation, are part of .................................. ...............

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