KPI and Reporting

For each failure event analyzed in the FMECA , is studied the feasibility of preventive interventions aimed at elimination or reduction in terms of frequency , duration and effects on the production process.

The alternative policies to Corrective proposals are:

Cyclic or Statistic Maintenance, carried out at intervals or number of cycles Set yourself . This policy is now followed mainly for the fulfillment of the Law, but it is still refined and streamlined where it appears the only possible or economically viable.

On Condition Maintenance (or Predictive or Inspection ) , aimed at early detection through regular checks sensory and / or instrumental . This policy is privileged from us , as much more performant and economic planning in a fixed timetable.

Improving Maintenance: one-off changes and improvements , aimed at the reduction and / or elimination of the fault type under consideration and its effects on the process. The selected changes are always operated under the supervision of the Planning ( feasibility , internal approval etc.).

For each alternative proposal to the Corrective using a specific template in xls, are defined in the same context, a timeline , a who - does -what , the resources required and the status of facility where the surgery is feasible (typically the machine stops or machine in operation) . The end result is the PMP ( Planned Maintenance Plan ) , importable on most existing SW.

At predetermined intervals (usually annually) MPPs are crossed with fault occurred , providing a complement to, correction or recalibration.

 

Our approach to Engineering Maintenance follows the guiding principles of TPM ® / MP ( Total Productive Maintenance / Productive Maintenance ) .

In summary :

• Prevention
• Monitoring
• Multidisciplinary Teamwork ( Maintenance, Production, Planning, Quality, Safety )
• Auto-Maintenance ( direct contribution to the maintenance and selected by Period)
• Continuous improvement (including training at all levels )

Operating logic and tools

The operating logic is that of RCM (Reliability Centered Maintenance ) , strategic subset of the TPM ® ( Total Productive Maintenance ) .

The tools are key failure analysis according FMECA ( MAGEC in Italian ) and the computerized management of the System.

The goal of reliability is pursued with a view to economy and thus on the basis rigorously analytical ( numerical ) and how to "see" the maintenance that follows directly from the principles of the TPM ® / RCM:

• Maintenance is the result of a project
• Maintenance is a phase of the Production Process
• The maintenance is a profit factor

 

The fault analysis is carried out using a version of "lighter" method FMECA (Failure Modes Effects & Criticality Analysis) The equivalent Italian acronym is MAGEC (Analysis of Failure Modes and Criticality of)

Our trainer guide the Multidisciplinary Working Group according to a questionnaire encoded internationally leading him to qualify and quantify analytically modes, causes, effects, frequency and duration of failures, as well as the impact on the production process. The criticality is evaluated with simplified formulas, personalized and "fast".

Other aspects of particular added value:

• The questionnaire also provides an analysis of the situation of spare parts, allowing you to correlate the duration of the state of failure.
• The version of "lighter" we propose allows switching in real-time analysis of faults in the design of countermeasures in terms of prevention, modification and improvement, and specific staff training.
• The innovative aspects are inserted with full continuity of past and capitalization. The Company heritage of knowledge and maintenance of KH productive, often only partially saturated, is then exploited and made productive through the techniques mentioned above.
• The use of maintenance failure (corrective) decreases to the optimal point of economic equilibrium.

At the end of the "virtuous triangle" whose vertices lie Maintenance, Operation and Design, in terms of modifications and improvements Working Groups are also encouraged to develop proposals on the maintainability of the items subject to analysis and to transfer their results to those responsible for design. This is in order to provide valuable information for the design of the drafting of specifications for new investments and the related manuals.

Essence of Maintenace Project is recalibrated periodically size and the optimal mix in the distribution of resources among the non-scheduled maintenance Corrective (at fault) and the planned activities for the prevention, programmed according to the three canonical modes:

• A fixed (or a number of cycles)
• On the basis of inspection sensory or instrumental (early diagnosis)
• Schedule one-off (modifications and improvements)

Maintenance is a scientific and technical discipline. So systematically uses terminology and units of measure specifications and unified.

In order for a system can be made measurable and comparable over time measured with itself and / or with similar situations, you need to uniquely define the parameters and their units of measurement. In more detail:

• The first parameter is the Political System Maintenance including allocating resources
• Units of Measurement System (UNI) are included in the Indices or KPI, always normed.

Objective of the Project Maintenance is an increase in non-episodic (ie consolidated over time) of the plant availability as a result of the increased reliability.