What is the best way to prioritize maintenance tasks in a manufacturing plant?

In any Manufacturing plant , maintenance plays a key role to ensure optimum uptime of plant infra.We can plan multiple Maintenance tasks based on risk assessment considering criticality for Safety , Health and Production downtime. We can make a risk priority Matrix based on above considerations and then further work upon it. There are various simple softwares available these days to track, monitor the status of all maintenance related tasks and it can further help us to evaluate maintenance related metrics to check effectiveness of the system.

Asses the criticality and impact on manufacturing activities. The most simple and sturdy process is to follow a checklist. Following checklists has been a rugged old practice to ensure fool proofing maintenance activities in any manufacturing unit. This helps support the production activities to plan as health of any machinery is dependent on its availability.

Após a avaliação de riscos, é crucial considerar a importância operacional de cada tarefa. Isso significa avaliar o impacto que uma falha teria na produção. Tarefas de manutenção em máquinas que são vitais para a linha de produção devem ser priorizadas. Por exemplo, se uma máquina é responsável por uma grande parte da produção e sua falha resultaria em atrasos significativos, a manutenção dessa máquina deve ser considerada de alta prioridade.

Upkeep of the plant machineries in a manufacturing should be a prime agenda for the Works Manager. Any downtime will result loss of production including economic penalty. Maintenance schedule should be adhered strictly and the fast moving spares should be held in inventory all the time. The machine parameters should be monitored meticulously to get advance information about any imminent breakdown.

We had over 1,000 machines running two shifts. Advantage we could take a machine off line during any shift and reduce production impact. Disadvantage, maintenance team small. Daily PM's were operator responsibility. This became weak link in system. Had to rethink overview of this, we had several QA folks out on the floor daily, added a quick process audit to daily tasks this corrected the issue and visibility. Machine OEE increased by two percent and breakdowns by two percent. May not seem a lot but was a significant improvement over a year of available operation hours.

The cost associated with safety is highest, then comes the quality and after that quantity. we should consider more cost of not doing rather cost of doing the maintenance.

Para priorizar tarefas de manutenção em uma fábrica, é essencial avaliar a criticidade dos equipamentos, estabelecer prioridades com base nisso, utilizar técnicas de gestão como a Matriz de Priorização de Manutenção (MPM), considerar a frequência de falhas e ponderar custos e impactos para garantir a eficiência operacional e a minimização de paradas não planejadas.

Depois de aplicar o princípio de Pareto, é essencial que a equipe de manutenção tenha o treinamento e as habilidades necessárias para realizar as tarefas de manutenção de maneira eficaz e segura. Isso pode envolver treinamento em técnicas específicas de manutenção, bem como desenvolvimento de habilidades em áreas como resolução de problemas e tomada de decisões.

Maintenance has Four Major activities Scheduled, Preventive, Predictive and finally Breakdown. The last one is to be least thought of If production has to run smoothly without any interruption. There needs to be a proper plan in place to have Health Checks and maintenance. Proper SOP and other needed documents need to be in place and need to be recorded. Schedule maintenance is an online check and monitor while the Machine is running for its lubrication, any corrective settings, and others. Preventive maintenance is scheduled and planned maintenance activities for complete check of the machine by stopping the production and completing the activity in given time. Predictive is looking at aging of parts and scheduling replace or change.

prioritization matrix allows to score tasks based on risk and resource requirements. Here's a simplified example: Priority = Risk Score / (1 / Resource Gap) Higher scores indicate a higher priority for the task. Resource Gap is the difference between available resources and those required for the task. A smaller gap signifies easier allocation of resources.

En una línea de producción manufacturera el priorizar los equipos y elementos imprescindibles es fácil. Solo clasifica en primeras posiciones el o los equipos que elevarían los costos del producto final si se detienen. Entonces ahora, lo realmente difícil y complejo es detener algo que no puede ser detenido afectando la Producción. Implementa equipos de apoyo redundantes, que realicen la misma función. Tenlos listos, aceitados, preparados para entrar en cualquier momento o bien cuando llegue el momento del Mantenimiento preventivo del equipo principal, trata a tu equipo de apoyo como si fuera principal.

Use a prioritizations matrix to score each task according to the risk and resource factors, and assign them a priority level.

Para priorizar tarefas de manutenção em uma fábrica, é essencial avaliar a criticidade dos equipamentos, estabelecer prioridades com base nisso, utilizar técnicas de gestão como a Matriz de Priorização de Manutenção (MPM), considerar a frequência de falhas e ponderar custos e impactos para garantir a eficiência operacional e a minimização de paradas não planejadas.

Para priorizar tarefas de manutenção em uma fábrica, é essencial avaliar a criticidade dos equipamentos, estabelecer prioridades com base nisso, utilizar técnicas de gestão como a Matriz de Priorização de Manutenção (MPM), considerar a frequência de falhas e ponderar custos e impactos para garantir a eficiência operacional e a minimização de paradas não planejadas.

Após a revisão e ajuste, é importante implementar melhorias contínuas. Isso significa que você deve estar sempre procurando maneiras de otimizar e melhorar o processo de manutenção. Isso pode envolver a implementação de novas tecnologias ou técnicas, aprimorando a eficiência do trabalho ou melhorando a segurança e a qualidade. A melhoria contínua é um processo contínuo que visa aperfeiçoar constantemente todos os aspectos da manutenção.

In my experience, this final step is the one that gets the least attention, at least where the attention should be focused. The term “stakeholders” is often used when recommending communication but can exclude the REAL resources who really have their fingers on the pulse of the problem: the operators. They hold the key to what is really happening in the manufacturing arena and are often overlooked by leadership. They should be an integral piece of this entire process.

Communication and collaboration helps in building relationships between operation and maintenance. Being open to feedback and input and communicating clear goals. Collaboration is intrinsically linked to the development of industry 4.0. The production and maintenance functions have thus come up with innovative and digital ideas to speed up production rates, reduce costs downtime and manage inventories.

5 La révision nous permet d'anticiper les réglages ou les dépannages qui pourraient nous surprendre en cours de production Faire les ajustements nous permet de standardiser les machines

Most important part is to follow the PM schedule & never miss it After that the equipments with no standby need to be thoroughly concentrated upon & addressed Thorough daily checks for vibration , alignment , lubrication etc & the ones out need to be tended to Costs are secondary consideration because the cost of plant break down will be higher than all others

Maintenance tasks should be sorted in three groups: 1. Safety critical 2. Production critical 3. Essential operation The priority of maintenance tasks can be determined considering the above three categories respectively.

Move away from a Reactive Maintenance towards Predictive Maintenance and even Preventive Maintenance. Such solution will ingest data from different sources and perform predictions on that data in order to produce maintenance incidents. Based on those predictions, the solution can automatically schedule and event help preventing those incidents by recommending different actions before the incident occurs.

Leverage past data. Have your past maintenance plans been effective or not? Adjust accordingly if schedules need to be improved and also consider preventative maintenance between production runs if you have an opening and planned downtime.