What are some innovative ways to improve maintenance safety?

Maintenance safety is a crucial aspect of mechanical engineering, as it involves preventing accidents, injuries, and damages to equipment and personnel. However, traditional methods of maintenance may not always be enough to cope with the increasing complexity, variability, and uncertainty of engineering systems. Therefore, some innovative ways to improve maintenance safety are needed to enhance the reliability, efficiency, and sustainability of mechanical engineering operations. In this article, we will explore some of these innovative ways, such as using digital technologies, applying human factors engineering, implementing condition-based maintenance, and adopting a proactive culture of safety.

1 Digital technologies

One of the most promising ways to improve maintenance safety is to use digital technologies, such as sensors, data analytics, artificial intelligence, and augmented reality. These technologies can help monitor the performance and health of engineering systems, detect potential faults and failures, predict and prevent maintenance issues, and provide real-time guidance and support to maintenance workers. For example, sensors can collect data on the temperature, vibration, pressure, and noise of machinery, and send it to a cloud-based platform for analysis. Artificial intelligence can then use the data to identify patterns, trends, and anomalies, and generate alerts and recommendations for maintenance actions. Augmented reality can then overlay relevant information and instructions on the workers' vision, using devices such as smart glasses or helmets, and help them perform maintenance tasks safely and accurately.

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Daniel Morais

Coordenador de Manutenção | Engenheiro de Confiabilidade | Especialista de Confiabilidade | Analista de PCM |
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Além das tecnologias mencionadas, é fundamental incorporar treinamentos regulares para os trabalhadores de manutenção sobre a utilização eficaz dessas ferramentas digitais, garantindo que estejam capacitados para interpretar corretamente os dados e seguir as orientações geradas. A implementação de um sistema de gerenciamento de ativos integrado permite rastrear o histórico de manutenção, facilitando análises retrospectivas e aprimorando estratégias futuras. A cibersegurança deve ser uma consideração central ao adotar tecnologias digitais, garantindo a proteção dos dados coletados e a integridade das operações.

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Tugberk Karan

Mould Maintenance Engineer @ Eldor Corporation | YetGen 23'2
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Digital technologies are pivotal in improving maintenance safety. Sensors, data analytics, AI, and augmented reality can monitor system performance, detect faults, predict maintenance issues, and guide workers in real-time. Sensors collect data like temperature, vibration, pressure, and noise, which AI analyzes to identify patterns and generate alerts. Augmented reality overlays information on workers’ vision, aiding in safe and accurate task execution.

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2 Human factors engineering

Another way to improve maintenance safety is to apply human factors engineering, which is the discipline of designing systems and processes that fit the capabilities and limitations of human operators. Human factors engineering can help reduce the risks of human errors, fatigue, stress, and injuries, and improve the performance, comfort, and well-being of maintenance workers. For example, human factors engineering can involve designing ergonomic tools and equipment, optimizing the layout and lighting of the work environment, providing clear and concise manuals and labels, and training and educating workers on the best practices and procedures of maintenance. Human factors engineering can also involve creating feedback loops and communication channels between workers and managers, and fostering a culture of teamwork and collaboration.

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Daniel Morais

Coordenador de Manutenção | Engenheiro de Confiabilidade | Especialista de Confiabilidade | Analista de PCM |
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Além da aplicação de engenharia de fatores humanos na concepção de ferramentas, é crucial considerar a diversidade da equipe de manutenção ao implementar essas melhorias, garantindo que as soluções sejam inclusivas para diferentes habilidades e necessidades. A realização de avaliações periódicas do ambiente de trabalho em colaboração com os trabalhadores permite ajustes contínuos, levando em consideração as mudanças nas condições e necessidades operacionais. A engenharia de fatores humanos pode ser estendida à implementação de sistemas de alerta e interação homem-máquina intuitivos, facilitando uma compreensão rápida e eficaz dos sinais e procedimentos de segurança.

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Tugberk Karan

Mould Maintenance Engineer @ Eldor Corporation | YetGen 23'2
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Applying human factors engineering is key to improving maintenance safety. This involves designing systems and processes that fit human capabilities and limitations, reducing risks of errors, fatigue, stress, and injuries. It includes designing ergonomic tools, optimizing work environment layout and lighting, providing clear manuals, and training workers on best practices. Creating feedback loops and communication channels, and fostering teamwork and collaboration also play a crucial role in this approach.

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3 Condition-based maintenance

A third way to improve maintenance safety is to implement condition-based maintenance, which is a strategy of performing maintenance activities based on the actual condition and performance of engineering systems, rather than on fixed schedules or predetermined criteria. Condition-based maintenance can help optimize the use of resources, avoid unnecessary or excessive maintenance, and prevent unexpected breakdowns and failures. For example, condition-based maintenance can use sensors and data analytics to measure and track the wear and tear of machinery components, such as bearings, gears, and belts, and determine the optimal time and frequency of maintenance interventions. Condition-based maintenance can also use diagnostic tools and techniques, such as vibration analysis, thermal imaging, and ultrasonic testing, to identify and locate the root causes of maintenance problems, and apply targeted and effective solutions.

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Daniel Morais

Coordenador de Manutenção | Engenheiro de Confiabilidade | Especialista de Confiabilidade | Analista de PCM |
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Além da implementação de sensores, considere a integração de sistemas de monitoramento remoto que permitam uma vigilância contínua e em tempo real do desempenho dos equipamentos, proporcionando uma resposta imediata a anomalias ou condições fora do padrão. A análise preditiva, utilizando algoritmos avançados, pode prever possíveis falhas com antecedência, permitindo a programação de intervenções de manutenção de forma proativa. A manutenção baseada em condições pode ser complementada pela aplicação de tecnologias emergentes, como a Internet das Coisas (IoT), que conecta dispositivos e equipamentos para uma coleta mais abrangente de dados em tempo real. A criação de um sistema centralizado para armazenar e analisar dados de manutenção.

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Tugberk Karan

Mould Maintenance Engineer @ Eldor Corporation | YetGen 23'2
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Implementing condition-based maintenance is a key strategy for improving safety. This approach performs maintenance based on the actual condition and performance of systems, optimizing resource use, avoiding unnecessary maintenance, and preventing unexpected failures. It uses sensors and data analytics to track machinery wear and tear, determining optimal maintenance times. Diagnostic tools like vibration analysis, thermal imaging, and ultrasonic testing identify root causes of problems, enabling targeted solutions.

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4 Proactive culture of safety

A fourth way to improve maintenance safety is to adopt a proactive culture of safety, which is a set of values, beliefs, and behaviors that prioritize safety as a core objective and responsibility of mechanical engineering. A proactive culture of safety can help prevent accidents and incidents, promote continuous improvement and learning, and enhance the trust and satisfaction of workers and stakeholders. For example, a proactive culture of safety can involve setting clear and realistic safety goals and standards, providing adequate resources and incentives for safety, encouraging reporting and feedback on safety issues, and rewarding and recognizing safety achievements and innovations. A proactive culture of safety can also involve involving workers and stakeholders in the planning, implementation, and evaluation of safety initiatives, and fostering a sense of ownership and empowerment for safety.

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Tugberk Karan

Mould Maintenance Engineer @ Eldor Corporation | YetGen 23'2
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Adopting a proactive culture of safety is crucial in improving maintenance safety. This involves prioritizing safety as a core objective, preventing accidents, promoting continuous improvement, and enhancing worker trust. It includes setting clear safety goals, providing resources and incentives, encouraging reporting on safety issues, and rewarding safety achievements. Involving workers in safety initiatives and fostering a sense of ownership and empowerment also plays a key role in this approach.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Mike Cucchiara

Senior Industrial Electrician/Senior Machine Maintenance Technician Marmon Utility
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Unfortunately human error and forgetfulness come into effect but if safety is made part of a performance review, or small incentive or bonus program people seem to remember... 😁

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What are some innovative ways to improve maintenance safety?

1

2

3

4

5

1 Digital technologies

2 Human factors engineering

3 Condition-based maintenance

4 Proactive culture of safety

5 Here’s what else to consider

Mechanical Engineering

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What are some innovative ways to improve maintenance safety?

1

2

3

4

5

1 Digital technologies

2 Human factors engineering

3 Condition-based maintenance

4 Proactive culture of safety

5 Here’s what else to consider

Mechanical Engineering

Rate this article

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