Your plant equipment is down. How do you get it back up and running?

EM UMA DAS EXPERIêNCIAS QUE TIVE, APóS OBSERVAR QUE EQUIPAMENTO ESTAVA INOPERANTE, FOI REALIZADA A INSPE??O CONVENCIONAL NO EQUIPAMENTO, AFIM DE VERIFICAR A POSSIBILIDADE DE VISUALIZAR ALGUMA FALHA APARENTE, BUSCOU- SE INFORMA??ES DOS OPERADORES SOBRE AS INTERCORRENCIAS NO PROCESSO, INFORMA??ES SOBRE O HISTóRICO DO CONJUNTO VIA SISTEMA DE ORDENS DE SERVI?O, E APóS REUNIR TODAS AS INFORMA??ES, ALéM DE OBSERVAR QUE EXISTIA UM PROBLEMA VISUAL DE QUEBRA DE ACOPLAMENTO, NOTOU- SE QUE O MOTIVO DA QUEBRA ERA O ESFOR?O QUE A TUBULA??O EXERCIA NO CONJUNTO, GERANDO VIBRA??ES EXCESSIVAS QUE DISSIPAVAM ATé O ACOPLAMENTO.

Proper diagnosis of the problem and find a lasting solution,is cost effective rather than just throwing parts at a machine, it's important to not be a parts changer and do a proper diagnosis and get it right the first time

Sin duda alguna la identificación es básica, pero no desde un solo punto de vista. Los resultados crudos y reales deben ser puestos a disposición de la alta dirección para que se tomen, las acciones pertinentes al nivel que sea necesario. Normalmente los problemas no son nuevos, mucho menos sus causas; pero casi siempre las acciones se han postergado por conveniencia de unos pocos. Todo problema necesita tener un plan de mejora, o nunca se resolverá adecuadamente.

The first step is to identify the problem and its root cause. You need to gather as much information as possible about the equipment, its symptoms, its history, and its environment. You can use various tools and methods to diagnose the problem, such as visual inspection, testing, measuring, reading error codes, consulting manuals, or contacting experts. You should also document the problem and its details for future reference and analysi

In my experience, I have noticed that talking to opertor of that specific equipment helps a lot, get as much info u can get from him on how did this problem happen, what changed or how did machine react to this problem, before it completely stopped. Then do your analysis regarding the specific part of the equipment.

Durante análise de causa raiz da quebra de acoplamenbto de uma bomba, foi realizada a análise termica da tubula??o e constatado que o tanque de água quente, que n?o operava fixado/chumbado em sua base, se movimentava durante a opera??o do processo, for?ando a tubula??o, estrutura e refletindo no acoplamento do conjunto. Foi observado que adicionando uma junta de dilata??o na linha de suc??o, a mesma absorveria a movimenta??o do conjunto, minimizando a falha que naquele momento era constante.

Se deben definir métodos de validación con plazos definidos en el tiempo, para verificar la efectividad de las acciones tomadas; de otro modo se pierde únicamente el tiempo y se desgasta la credibilidad de las acciones y del equipo definido para las mismas. También se deben verificar que las mediciones y los plazos de las mismas son representativos en el tiempo, no vale tomar resultados de datos que no son verificados y/o actualizados.

The second step is to isolate and fix the problem. You need to follow the safety procedures and protocols for your plant and equipment. You should also have the right tools, parts, and skills to perform the repair. You can use different techniques to fix the problem, such as adjusting, cleaning, replacing, or upgrading components. You should also verify that the problem is solved and that the equipment is functioning properly

Safety First: As in any equipment has potential to damage personal or property, first we need to isolate it mechanical or electrically, depending on scenario thats needed and then start working on problem

The first step is always problem identification. Then you isolate and fix the issue. Once you get the equipment up and running again it is always beneficial to meet with your team to come up with the best mistake proofing measures to prevent future interruption to equipment up time.

Após a inser??o da junta de dilata??o do case da bomba de água quente de um determinado processo produtivo, o conjunto ficou em observa??o durante 6 meses, através de inspe??es periódicas, com o intuito de observar o comportamento e a eficácia da analise de causa raiz. O equipamento voltou a operar dentro dos limites de vibra??o e n?o houveram mais historicos de quebra do acoplamento.

To restart the equipment and monitor its performance You need to follow the start-up procedures and checklists for your equipment. You should also test the equipment for its functionality, efficiency, and quality. You should also observe the equipment for any signs of abnormality, such as noise, vibration, heat, or leaks. You should also report the problem and its resolution to the relevant stakeholders, such as managers, operators, or customers.

If it is not an electrical failure then next step is restart machine and look for unusual movement, noise or vibration. or any other kind of obstacles which are blocking sensors and machine is just not starting because safety sensor is off.

Méthode résolution de problème Méthodes de résolution de problèmes appliquées au diagnostic de pannes - la méthode S.O.R.A. (Situer ? Observer ? Réfléchir ? Agir) - recueil d’information - la bo?te à outils : QQOQCPC, Les 5 pourquoi, l’arbre des causes, l’analyse fonctionnelle, Pareto, le plan d’action, le compte-rendu Approche technique - Le GRAFCET comme outil de dépannage d’automatisme séquentiel - La visualisation - Les techniques de mesure : - Méthodologie de dépannage électrique au voltmètre, méthode par dichotomie - Rappel sur les mesures de continuité au voltmètre sous tension (valeur de la d.d.p.) ou à l’ohmmètre hors tension (valeur ohmique fil coupé ou non)

Durante a análise de falha, foram levantados os custos de interven??o, insumos consumidos, valor de produ??o perdida, e com isso viabilizar o investimento de parada programada, material e m?o de obra, para eliminar o problema encontrado.

The fourth step is to analyze the problem and its impact. You need to evaluate the causes and consequences of the problem. You should also measure the downtime and its costs, such as lost production, wasted materials, or delayed delivery. You should also identify the opportunities and actions to improve the equipment and prevent similar problems in the future

Foi inserido no processo a inspe??o termografica mecanica e de processos, com a finalidade de observar o comportamento mecanico e a dilata??o térmica do conjunto rotativo. Além disso, as inspe??es preditivas pela técnica de vibra??o foram reduzidas para cadência mensal, com intuido de evitar paras n?o programadas.

The fifth step is to implement preventive measures to avoid equipment breakdowns. You need to plan and schedule regular maintenance and inspection for your equipment. You should also follow the best practices and standards for your equipment and industry. You should also train and educate your staff on how to use, maintain, and troubleshoot the equipment. You should also update and upgrade your equipment as needed

The sixth and final step is to review and improve your equipment performance and reliability. You need to collect and analyze data and feedback on your equipment, such as availability, productivity, quality, and safety. You should also benchmark your equipment against your goals and expectations. You should also implement continuous improvement processes and tools, such as root cause analysis, corrective action, or kaizen, to enhance your equipment and plant operations

pack up plan must be ready for implement in case of equipment failure and all operation team trained in case such that that in worst case

To me, to quickly restore plant equipment, diagnose the issue, ensure safety protocols, and engage skilled technicians for efficient repairs. Check spare parts availability, order promptly if needed, and maintain detailed documentation of the repair process. Conduct thorough testing post-repair and implement preventive measures to minimize downtime and prevent future issues. Coordination and swift action are key to efficiently getting the plant equipment back up and running.

In my experience, plant facilities equipment must be running at safe side 70%, is imperative to have back up for preventive maintenance window time. Example Pressurized air compressor , back up equipment must have by pass valve systems . Production equipment must be capacity by demand or Run time policy to allow time for pm and or dt. Definitely spare part strategy and TPM are key in equipment preservation. My 5 cents

Like this Situation,Find the Quick Alternative Solution For Problem, Analysis Previous Track Records For Root cause and keep Track Records For Future and Downtime analysis, Ensure Safety and Protocols ,Arranging Skilled Maintenance Team To solve Problem ,Check Spare availability and Quantity For Current Future use, Follow regular and Scheduled Preventive Maintanence to Avoid Future Brake Down and ensure Plant Running Smoothly

1. "Did you try turning it off and on again?" if Yes goto 2. if No goto 1. 2. Is it working? if yes "Keep Calm and Carry on". if No "Freak out!"

To get the plant equipment back up and running: 1. Assess the issue. 2. Ensure safety. 3. Notify relevant personnel. 4. Troubleshoot and identify the problem. 5. Repair or replace faulty parts. 6. Test equipment functionality. 7. Document maintenance activities. 8. Implement preventive measures. 9. Provide training for personnel. 10. Continuously improve maintenance procedures.