PREVENTIVE MAINTENANCE AS A COMPETITIVE FACTOR

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The current standard requirements regard preventive maintenance as an integral part of a company-wide quality offensive. In Section 8.5.1.5 of IATF 16949: “Total Productive Maintenance (TPM)”, an entire chapter is dedicated to the topic of integrated plant management.

This section is all about the clear requirement for a documented and proactive system to ensure the safety and availability of the production facilities. Section 8.5.1.6 extends this approach to cover the management of production tools as well as testing, gauging and manufacturing equipment.

IATF 16949 is based on DIN EN ISO 9001, in which Section 8.5.1 also demands that preventive maintenance be carried out at all manufacturing companies across all industries. Briefly stated: For certified companies, there is no way round a reliable maintenance management system.

In-house developments, for example, maintenance planning using Excel, provide an initial overview of the required measures. As soon as it comes to scheduling and the allocation of specialist personnel, taking into account the current order situation, it often becomes obvious that the task is too voluminous to be implemented efficiently and in real time when considering the dynamic production conditions. Professional software solutions, such as Böhme & Weihs’ maintenance management module, promise to provide integrated control of all your maintenance, inspection and repair measures

PREVENTIVE MAINTENANCE INVOLVES ALL YOUR PRODUCTION RESOURCES

Our maintenance management module changes the entire maintenance process through its intelligent mode of operation – no longer reactive, but integrally preventive. To ensure and increase overall equipment effectiveness (OEE), all the resources which are essential to the production process are included.

The focus is, therefore, not only on plant, machinery and tools, but also on personnel qualifications with validity periods and aids, such as forklift trucks, scales and pallet jacks. And as far as the management system is concerned, Total Productive Maintenance goes one step further, i.e. across all processes: Without exception, everything that is subject to regular inspections can be reliably monitored – from fire extinguishers to elevator systems.

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AUTONOMOUS MAINTENANCE – SUPPORTING MACHINE PERSONNEL

Our maintenance management tool actively supports the basic concept of autonomous maintenance and makes a major contribution to increasing plant efficiency. Existing resources are optimally deployed: Routine maintenance measures – such as lubrication or cleaning work – no longer have to be carried out exclusively by qualified maintenance personnel but can be assigned to production employees.

Our maintenance management module guides these employees through the work schedules using pictures, linked process instructions and structured work steps. All the measures are displayed as a checklist directly at the group or machine terminal – so that an eye can be kept on all the respective tasks.

Autonomous maintenance offers the potential to considerably increase maintenance efficiency: The burden is taken off your skilled maintenance personnel, the workload for external service providers is reduced and the reliability and service life of the equipment as a whole is increased.

NETWORKED COMMUNICATIONS: EFFICIENT AND TRANSPARENT

Networked interaction, in line with Industry 4.0, ensures optimum process workflows with no time delays. Two examples: Are wear parts required for the upcoming maintenance job? Our maintenance management module knows exactly what is required at what time and in which quantities and automatically sends the request to the ERP system which then immediately reserves the required material for the maintenance job.

If the inspection and maintenance of your machines, systems or tools shows that a repair needs to be carried out, there is no time to lose. Downtime must be kept as short as possible. The maintenance management system then automatically sends a requirement notification to the ERP system based on the stored BOMs. The stock inquiry is then immediately carried out and the required parts for the repair job reserved or ordered straight away.

INTERACTION BETWEEN CAQ AND MES ENSURES CONFORMITY WITH THE STANDARDS

Our maintenance management tool is available for deployment in two versions:

  • Stand-alone, as a complete preventive maintenance management tool
  • As an integral part of our WEB.MES MES solution in accordance with VDI Guideline 5600

Both application scenarios can also be extended by adding CASQ-it CAQ – for a result ranging from intelligent interaction between your CAQ and maintenance management systems to a fully integrated WEB.MES, preventive maintenance and CAQ network.

Regardless of which application scenario a company finally decides on: Our standard-compliant maintenance management module meets all the requirements of a Total Productive Maintenance system in order to minimize downtimes and increase effectiveness and plant availability. This also extends to testing and measuring equipment, if it is used in combination with our CASQ-it CAQ system – exactly as required by ISO 9001 and IATF 16949.

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