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PUMPS, VALVES & ACTUATORS ADOPT A PREVENTION-FIRST APPROACH
Matt Dixon, Senior Marketing Manager – Industrial Automation EMEA from Norgren, outlines what to consider when establishing preventative maintenance measures
mean manufacturers are searching for the solutions that can optimise production performance, increase efficiencies and cut costs. Preventative maintenance measures can play a pivotal role in identifying potential problems and also aid system optimisation. ‘Failing to plan is planning to fail’ according to
P
the old adage. And this is an apt saying when it comes to optimising system performance based on a ‘maintenance matters’ philosophy. The proven pathway to reducing
maintenance-related issues is to plan, devise and implement a robust preventative maintenance programme. By spotting and solving smaller issues before they can cause greater impact, better system optimisation outcomes are possible and, with it, enhanced operational efficiencies overall. A prevention-first approach also reduces
pressures on maintenance teams often working to tight deadlines. Adopting a preventative maintenance schedule ensures that all elements of the production process are under constant review, with the overall objective of eradicating instances of unexpected failure. There are several approaches engineers can
take to establish and operate a preventative maintenance programme. Three key areas must be considered to build towards better outcomes. Using data for intelligence-based decision
making – Through the increasing use of industrial digital technologies, engineers can now access volumes of essential information about components’ operational condition and performance. The data derived from smart, connected products and devices placed within production lines provides real-time, highly accurate status information which operators and managers can assess and interrogate so that intelligence-based decisions can be made. The data allows for performance comparison
against critical KPIs and helps determine if remedial steps need to be taken with a faulty component before a potential larger issue occurs. As proof of the validity of this approach,
roduction system performance is under continual pressures. Rising energy costs, as well as the impact of unplanned downtime,
a recent Government report estimated that the use of industrial digital technologies can help to reduce machine downtime by between 20 and 30% and cut plant maintenance costs by between 15 and 25%. Learning and improving – The
establishment of a preventative maintenance programme provides the foundation for an ongoing cycle of continuous improvement. The knowledge gained by analysing the performance of important components in varying environments, their reactions to temperature changes, altered workload requirements and time taken to see wear and tear impact, can both inform and then guide plant operations and drive up efficiencies. Another benefit of a preventative
programme is the ability to identify high energy consuming components and take the opportunity to replace them with more energy efficient solutions. At a time of escalating energy costs, taking such a holistic view about where energy and cost can be saved during production processes can help deliver tangible savings to the bottom line. A good example is the use of compressed
air during the manufacturing process. Despite its broad use, it remains one of the most expensive forms of energy with a typical 500l/ sec unit consuming approximately £40,000 of electricity per annum. The smallest unidentified and unrectified leak within the compressed air system
compromises performance, makes production less efficient and increases costs that could otherwise be saved. Recording the data is just a part of the
overall drive for better efficiencies. However, by partnering with an expert product supplier - one who can help investigate component performance data - means plant managers and engineers can work collaboratively to find solutions and answers that will help establish a competitive edge, increase productivity levels, optimise performance, and lower costs. Only as strong as your supply chain – In
the event of an issue leading to downtime, it is vital that manufacturers have confidence in their supply chain and that it can respond in a timely manner and solve the issues. Usage of and ready access to appropriate Service kits can extend component life, but when needed, spare parts should be available without delay, to minimise the impact of shutdowns. Engineers and plant managers should
work to ensure that their supply chain offers sufficient stock levels, provides easy to access technical support and has the back up of field engineer resource that can attend if required. Norgren offers a helpful preventative
maintenance checklist that can aid the establishment of robust maintenance programmes. Taking a holistic approach, it guides plant operators on what to look for, check and investigate so that a slight issue is resolved before it becomes a bigger challenge. It also supports the cycle of continuous improvement. To obtain a copy of the checklist, visit:
https://new.norgren.com/en/support/blog/ maintenance-matters-are-your-plans- in-place
Norgren
new.norgren.com
DECEMBER 2022/JANUARY 2023 | PROCESS & CONTROL 29
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