How can you determine the optimal maintenance frequency for your equipment?

Something I have noticed in the industry is that there is generally a general maintenance plan for all equipment. Although this could help with maintenance planning, I would suggest having a look at all the equipment and categorizing wich will have the most impact if broken and wich will cost the most to replace when broken. Once this has been done you can then set up a maintenance plan for each machine according to its design and maintenance needs as each machine is different. Having a proper maintenance plan for each machine will help you understand the dynamics of the machine and how crucial its own maintenance plan is prolonging its lifespan as much as possible.

One thing I found helpful ,is implementing Condition monitoring systems with their components to contribute the efficiency and trouble-free operation of machines and plants in industry. As we moving to industry4.0 ,distributions in the production process due to unplanned downtimes ,can be prevented through the use of smart sensors. consisting of data acquisition, data processing, visualization and evaluation. The focus is on quick and easy installation, especially in existing plants. Less costive and data feedback is based on real-time!

There is no one size fits all maintenance strategy. You must take a hard look at your industry, your production goals. your budget, your staffing, your specific challenges and so on. Use this knowledge to customize a strategy that fits your goals.

maintenance strategies can be adopted for equipment, depending on its characteristics, usage, and criticality. Reactive maintenance is when maintenance is performed after a fault or failure occurs. This strategy can be suitable for low-value, non-critical, or easily replaceable equipment, but it also has the potential to cause high downtime, repair costs, and safety risks. Preventive maintenance is when maintenance is done at regular intervals based on a predefined schedule. This can be beneficial for equipment that has a predictable wear and tear pattern, . This strategy may be suitable for equipment that has a high impact on the plant's objectives but requires thorough analysis and planning.

I would categorize my equipment in terms of their criticality when it comes to its operational requirements, cost to production if it were to fail, cost of unplanned maintenance, availability of spares, safety to personnel and plant as well as harm to the environment just to name a few. Once that is done, I can then assign an optimal frequency for each equipment according to their order of criticality as there are different types of maintenance strategies. Once the strategies have been put in place and running, I would initiate maintenance strategy review sessions to check not only the effectiveness of the strategies but also to review the frequency and implement any changes or improvements that may arise from those sessions.

OEM suppliers will gladly help with intervals for inspections and predictive maintenance strategies. s well as lubrication schedules. But your own specific needs and abilities dictate PM's and so on. You set the maintenance schedule to the best of your knowledge and experience. But your system must be fluid enough to adapt to changing needs and conditions.

Age-based models, like replacing furnace filters regularly, address the increasing failure rates equipment experiences as it gets older. Usage-based models, on the other hand, focus on the equipment's workload. You can leverage manufacturer recommendations, equipment history, and your own maintenance goals to determine the best approach. Remember, preventive maintenance is key! By routinely inspecting, cleaning, and lubricating your equipment, you can catch minor issues before they snowball into major problems and costly repairs. Overall, the optimal maintenance frequency is about striking a balance between preventing breakdowns, keeping your equipment running smoothly, and avoiding unnecessary maintenance.

The production schedule is your primary driver. Its "why we are here". You must then look at staffing and cost. Sometimes maintenance is required during off shift times, weekends, holidays.

Um bom plano de manutenção vai manter a disponibilidade física do equipamento em pleno funcionamento, mantendo os padrões de produtividade da empresa