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预定的PM确实有效吗?

True preventive maintenance lies in accurately monitoring and counting issues and corrective actions over 时间.

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这个问题看起来很简单,答案却很明显,但是,在我们的模具维护培训课程中表达的广泛观点可能会让您感到惊讶。机械常识当然意味着预防性维护(PM)。为什么不’是吗?因此,我们还要问,它对您有什么作用?是否消除了产品缺陷或模具损坏?它会减少维护和人工成本吗?它使OEM满意吗? PM的实际好处还不清楚。

During our maintenance strategy discussions, we ask which attendees have a structured, adhered-to PM program in place. Typically, a few hands go up. Then we ask how many have a PM schedule that has been validated over 时间 to be effective based on mold- and part-defect frequencies, corrective-action costs and cycles, or some form of odometer. Typically, no hands go up. Some shops have such schedules but agree that they have not been proven to be much more effective than a decent cleaning, and even that is a struggle to get accomplished on 时间. Still other shops run the mold until it breaks down or until the order is complete, and then perform PM. 

For most, 预定的 PM occurs when a mold is stopped after a certain number of cycles or parts have been run, and then it is cleaned and greased. Seldom does anyone bother to scour past workorders filed away in cabinets looking for repeated product or mold issues that cause ongoing defects and unscheduled mold stops. Some shops also don’t take 时间 to review the last shot, or take measurements of critical seals or tooling fits to proactively ward off problems. The depth or level of the PM is typically based on what someone thinks the mold needs. It is a subjective decision rather than one based on historical maintenance data.

Because there are so many things that could stop production and/or cause product defects at any 时间, shops need to understand that regular cleanings won’不能达到每一个成型者’s 
goal of efficiently producing quality parts on 时间. The bottom line is that molders and molds have problems that will not all be solved through 预定的 cleanings. 模具require more attention.

因此,如果不定期清洁’答案是什么?真正改善的关键因素在于能够随着时间的推移准确地监视和计数问题以及纠正措施的能力,“time”模具周期数或生产的零件。模具的性能不仅仅取决于模具的清洁次数,还取决于缺陷和模具问题的监控,以创建可行的目标清单,用户可以在将模具取出用于PM时集中精力。对于车间的持续改进,当务之急是要能够相对轻松,准确地确定其首要问题,因为要监控的变量太多,就无法持续有效。维护策略必须积极应对停产问题。 

从哪儿开始
Many 时间s shops want to improve their root-cause analysis when they should first make sure they are chasing the things that are worthy of their 时间 and effort. When a mold lands on a bench for PM (or for any reason) repair technicians should use that 时间 to utilize and grow the knowledge base about that mold. Part of a reliability-centered maintenance strategy (the process used to determine the most effective maintenance approach or to 恩 sure that systems continue to do what their users require) is identifying issues instead of blindly performing PM without being up to speed on historical problems. 

首先列出导致模具停止的原因。在一个好的维护系统中,这将包括大约30个原因,这些原因被归类为“scheduled” or “unscheduled.”使用标准工单表格的商店可能已经发现典型的工单标题通常是键入语句,而不是标准术语。文档规范的一部分是要求负责创建模具PM或模具工作单的人员使用可排序和可度量的标准术语。我们只是不’不要像我们应该那样使用数据。例如,当维修技术人员输入“fixed it,” “done” or “completed”对于纠正措施的解决方案,可以在全球范围内查看此信息,但是它实际上完成了什么?您会在全球范围内遇到混乱的维护工作,因为时间,金钱和资源浪费在重复性问题和其他贯穿裂缝的缺陷上。

另一面“fixed it”维修技术人员的工作时间长,细节过多,他们会尽力做到最好,并为随后的技术人员提供所需的全面知识,以及对模具进行哪些维护。这里的问题通常是这些冗长的故事中缺乏清晰的技术文章。它们通常是用非标准语言编写的,这需要更长的时间才能解密,而下一位技术人员不会’无法获得他需要的所有数据。 

接下来是计算鼠标点击次数,这是一种用于衡量“cumbersome”维护系统的级别。例如,在用户最终能够访问所需信息之前,所需的更多点击将决定其对任何维护程序的喜爱程度。数据库崩溃和运行缓慢的系统也不受欢迎。将所有这些情况加起来,您就可以保证在维护日志中输入固定类型的条目。所需的点击次数越多,将使用的系统越少。

多年来,我们并没有试图减少已添加到电子维护系统中的所有重大功能,但是,只要商店使用自由格式的文本字段脑垃圾收集程序收集关键的维护核心数据,而不是使用标准化的商店语言,将继续努力开发真实,可衡量的指标并真正主动。 

That is the answer: to develop and use standard terms. Make a list of these terms and hang them up for all to get familiar with and use on a daily basis. It will take a meeting or two among quality staff, the molding manager and the toolroom manager to create terms for the core areas, but the 时间 spent on this will be recouped many 时间s over with more accurate data and the ability to quickly sort and count 恩 tries. 

这也将需要数据纪律和 员工问责制,但这将使车间能够为所有模具创建缺陷目标和目标,并利用有关其模具如何运行以及需要进行哪些维护才能使其可靠,高效地运行的累积知识。

简短而重要的标准术语列表包括:
•模具停止(计划的和非计划的)
•缺陷类别和术语(电气, 机械,产品,过程,维护等)
•工装条款(喇叭销,引导销,导向衬套,互锁件和上子)
•纠正措施条款(替换,清洁,返工,制造,抛光等)。

The tooling and labor costs should be associated with every defect, so a shop knows which defects are costing the most money in corrective-action repairs. Understanding which issues are stopping it from efficiently producing quality parts on 时间 can help a shop to develop a list of ongoing targets to post and assign to the repair technicians, as opposed to asking them to fight fires every day. This is what true proactive maintenance is all about. Only when the shop has a better handle on what is stopping/slowing production and the real costs of maintenance, and when it can relate these to known cycle counts, can it create validated and effective PM work instructions for its molds. 

如果您要做的只是定期清洁并在模具上进行PM,那么您将把所有缺陷,计划外的停机,高模具成本,高人工成本,质量问题以及对Murphy先生的总体压力,星型排列,月亮,十二生肖—换句话说,就是机会。这些方法中,没有一种方法能像使用精确数据进行维护跟踪一样有效。

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