What do you do if your plant equipment isn't performing as expected?

Identify the root cause of equipment low efficiency by conducting RCA techniques. After identifying the root cause, look for possible countermeasures to address the issues. Implement the best countermeasure by analysing the fault data and adding the team's valuable experiences.

I do agree! The first thing is investigating the cause of the problem. You may start by asking oneself what's happening that shouldn't be happening or what isn't happening that should be happening 🤔 This may require use of simple tools, equipment or mere observation by a skilled professional. An experienced and skilled professional can identify or point out such problems with much ease. After identifying the problem or source of problem we will go on to find the root cause of the problem. For example, one may find that a sensor is causing an issue on the line. This could be a result of many things like wrong type of sensor, wrong environment or wrong installation. We then solve the issue permanently.

I have work on identity the issue all types machine production and quality and data analysis or safety and utility and used various tools and method or testing

A solução de um problema sempre terá como inicio o entendimento dele, portanto identificar a causa raiz ou as causas raízes é sem dúvida o primeiro passo na resolução de um problema.

The first step is to identify the issue that is affecting your equipment performance. Is it a mechanical, electrical, or software problem? Is it affecting one component, a system, or the whole plant? How severe is the impact on your production, quality, or safety? You can use various tools and methods to diagnose the issue, such as visual inspection, testing, measurement, data analysis, or consulting manuals and experts. The more specific and accurate you can be about the issue, the easier it will be to find a solution.

The troubleshooting depends upon the nature of the equipment and also the nameplate which gives the specs of the same equipment. 1. Visual inspection 2. check for power presence 3. Check for blown fuses 3. Do certain required tests for the equipment 4.

Yes determine what has caused the issue. Look at all the simple stuff before tearing into it. A lot of times it's a bolt that has come loose or debris built up.

There is more to the equipment performance than just the hardware. Remember the "dirty dozen" and exclude operator induced errors wherever possible.

I agree but as an equipment operator you can only advice the mechanical team what might be the root cause because you role is to operate an do dairy checks of the equipment

I have a saying; "It's usually the simple stuff that gets you." Again, this applies in the field, because based on customer calls, you know where - approximately - to start searching for a reason why no one has TV or internet. Look for the obvious, based on what you know about the locale. Then go to the next spot past it and check it out for damage, and fix it if found. Minimizes down time, maximize customer satisfaction.

In a situation where a bolt works loose make sure they are torqued down to spec, maybe it needs loc tight, verify it's the proper bolt for that spot, what's causing it to work loose ect. If it is debris built up and it can't be eliminated then implement a cleaning schedule for that area. Do the same for a worn out part. Why caused it to wear out, can we lube it or does it need to be cleaned and maintained more frequently. Is there a better built part we can replace it with

1. Must have. 2. Should have and 3. Nice to have. There are quite a few ways to skin the cat, so choose two of the three ( good, fast and cheap) wisely.

For solution implementation first we have to read drawings, install spares after cleaning, after installation and testing we have to monitor the situation until it reaches its peak.

Repeat the step 1 actions to confirm positive improvements. Really shouldn't take any extraordinary measures unless you messed up on steps 2 and 3.

Optimizing your equipment is the best way to get the best out of your plant equipment and always use the N + 1 philosophy for critical operational equipment incase of sudden breakdown. Don't overload your equipment or exceed the safe limits, plan your maintenance strategy, ensure more PMs than CMs, and readily availability of critical spares

_Understand the System:_ Gain a solid understanding of the machinery you’re dealing with. Familiarize yourself with its design, components, and operating principles. This knowledge will help you identify deviations from expected performance. _Develop Possible Causes and Theories:_ Based on your understanding of the system, generate hypotheses about what might be causing the problem. Consider factors like wear and tear, component failure, or process changes.

1. Are the operators properly trained to handle the equipment? 2. Are the Pm's and Cm's properly executed? 3. Are the OEM specifications aligned with the equipment usage? 4. Are the technicians competent to carry out the repair work? 5, Are the correct spare parts used when a failure occurs to administer repairs?

Always, and I mean it, ALWAYS put the reliability and maintenance before any production team goals. Price to pay for minute production wins is way too high in the long run. Stick to the maintenance schedule, and later the maintenance budget will thank you for that.

My experience has always told me to analyze the fault and refer to the manual. Make absolutely sure the machine is being operated as instructed and any adjustments that are defined are to spec. Always go back to the basics when you find your equipment lacking in some way. I've been in factories where after 5 years all of the bushings in a machine were completely wore down and causing reliability issues all because a previous tech liked the way the machine ran better out of spec. These bushings should have lasted 10-15 years. Old habits are hard to break and sometime even harder to find. Consult the Oracle(manual).. ;)