Overview of maintenance
strategies
»Reactive«, »proactive« and »condition-oriented« are three strategies
used for machine maintenance. Many companies still choose a reactive strategy,
only taking action once a fault has already occurred. This will affect machine
availability accordingly – the more complex the fault, the longer the period
during which machining center will be unable to manufacture.
EfficiencyServices
enable improved reactive maintenance with reduced downtime. Using RemoteLine,
which provides direct access to the machine data, the experts at CHIRON Group
Service can identify and resolve faults, in many instances directly and without
making a service call-out. When combined with proactive, cyclic maintenance,
this can further reduce unplanned downtime.
However,
it will take additional measures to increase machine availability in the long
term. Namely, a long-term strategy to reduce downtime towards zero and to
consistently maintain the machine in its best condition. This is where
ConditionServices come in.
ConditionServices: A
three-step strategy
ConditionServices
are not a one-off solution but rather a long-term process towards consistently
high technical availability – with the additional benefit of fixed, foreseeable
costs.
Step one: Analysis of the
machine and service history
To
start with, the service managers take a look back and closely inspect the data
of all of the components which influence the manufacturing quality. Which
faults have there been in the past?
Have
certain components – as illustrated in the figure by the tool changer and
drivetrain on the Y-axis –
been disproportionately affected? The service managers look into the details of
any abnormalities, research their causes and recommend how such a fault can be
avoided in future. For example, this could involve retrofitting or adapting the maintenance
plan to the tool changer with an enhanced wear parts package.
Step two: Cyclic recording and
data evaluation
In
the next stage, all potential sources (new and existing CHIRON and STAMA
machines) are incorporated into a comprehensive maintenance strategy based on
ConditionLine, a module from the SmartLine range. The digital system
automatically analyzes all of the machine data that is relevant for the machine
to operate reliably.
ConditionLine
is directly integrated into new machines. On the other hand, existing CHIRON
and STAMA systems can be upgraded with hardware and software via a retrofit.
For older machining centers which do not have the technical prerequisites for
integration or continuous data recording and evaluation, HealthCheck is the
correct instrument to use. HealthCheck adds additional appointments to the
annual maintenance schedule so that the CHIRON Group Service can manually
inspect the machining centers on-site. The managers use the results to make
well-founded recommendations for maintenance work and to exploit optimization
potential.
Step three: Maintenance based
on the machine condition
ConditionLine
constantly monitors and analyzes the condition of the machine and detects
irregularities in operation at an early stage. The more machines that are
integrated, the less time it will take to create a comprehensive, reliable
database. Another factor is time. This is because, with every passing month and
year, potential disruptive factors can be predicted with greater accuracy. The
maintenance scope and planning can therefore be adjusted to the current
requirements in an accordingly dynamic and increasingly precise manner.
Technically availability will rise increasingly, with the additional benefit of
fixed and foreseeable costs.
Buy or subscribe?
With
ConditionServices, customers have a choice of different payment models. The
ConditionLine software and necessary hardware can be purchased in the
traditional way via a retrofit, or a subscription can be taken out for the
contract term.
In
addition to ConditionLine and/or HealthCheck, the following services are
included in all price models: Analysis, inspection and maintenance of the
machining centers, as well as spare and wear part replacement.
Improving performance by
combining modules
The
third element for increased overall equipment effectiveness are
ProductivityServices.
In this case, the service
managers scrutinize the manufacturing process, including all of the areas
involved such as hardware and software, automation and process and set-up times.
This indicates any areas of untapped potential and these can be exploited using
appropriate measures, particularly by integrating additional SmartLine modules.
Want
to find out more about SmartServices?
Johannes Hellstern, Digital
Services Product Manager at the CHIRON Group, would be happy to answer any
calls or e-mails.
Johannes
Hellstern
Phone:
+49 7461 940-3728
[email protected]
