Here's how you can effectively analyze and troubleshoot complex machinery issues as a Plant Engineer.

Today, modern machines are often equipped with advanced diagnostic tools. These tools are designed to collect real-time data on various operating parameters of the machine. Integrated sensors monitor operational conditions and transmit detailed information that is essential for precise problem diagnosis. Using these tools to your advantage is essential for gaining insights into performance metrics and identifying irregular patterns that may indicate underlying issues. Statistical analysis and machine learning algorithms applied to collected data can even predict failures before they occur, enabling proactive corrective measures to be implemented.

When troubleshooting a system, ask yourself, "What changed?" many techs make matters worse when they change settings. When in the what changed mode do a visual inspection, to ensure power, air, etc is present. Check interlocks and E-stops are functioning and in their proper position. Use your nose. Are there any smells coming from actuator coils? look for leaks and check pressures. Many times small issues are made worse by not making rudimentary checks. There's a reason IT departments ask you to turn on and off your computer, your screen check the plug, etc. It's because most of the time it is something simple that was overlooked. Major issues are easy, you can see them. Slow down and check the basics so as not to exacerbate the issue.

Antes de mergulhar nos reparos, é crucial coletar o máximo de informa??es possíveis sobre o mau funcionamento do maquinário. Isso inclui a revis?o de dados operacionais, histórico de manuten??o e quaisquer mensagens de erro. Ao entender o contexto em que o problema surgiu, você pode identificar possíveis causas. As máquinas modernas geralmente têm ferramentas de diagnóstico integradas que fornecem dados valiosos. Use essas ferramentas a seu favor para obter insights sobre métricas de desempenho e padr?es irregulares que podem indicar problemas subjacentes.

Take a minute to review the previous issue of the machine, before we conduct troubleshooting, we need to visualize the part where the issue is.

Steps are simple Do visual inspections gathering data Before diving into repairs, it's crucial to collect as much information as possible about the malfunctioning machinery. This includes reviewing operating data, maintenance history, and any error messages. By understanding the context in which the issue arose, you can pinpoint potential causes. Modern machinery often has built-in diagnostic tools that provide valuable data.

Take this action, C.I.L.T.R C is to Check I id to inspect L.lubricate T.tightening R.replace This idea very is effective in terms prevententive maintenance

Através da manuten??o Preditiva onde entra a Análise Termográfica, ira detectar o problema o mais rápido possível fazer um levantamento da causa e solu??o.

Preste muita aten??o aos componentes que s?o propensos a falhas, como correias, engrenagens e conex?es elétricas. Procure sinais de superaquecimento, contamina??o ou vibra??es incomuns. esse e o passo correto pra um bom funcionamento da Maquina

Commisioning or re-commissioning equipment is incomplete without proper functional testing. These tests prove that the equipment will perform without issue according to design when called upon.

. Seja cauteloso e siga os protocolos de seguran?a para evitar mais danos ou acidentes. Esses testes podem fornecer feedback ao vivo e ajudá-lo a entender a rela??o entre vários componentes e sistemas dentro da máquina.outro pormenor a comprar

You also have to be attentive and keep checking the parts that are most likely to fail, such as sensors, fuses, lubrication, oil levels, etc.

Essa ferramenta de análise é extremamente importante para as tomadas de decis?es do gerenciamento de manuten??o. Uma análise bem realizada identifica possíveis falhas futuras e gera modos de bloqueio para que n?o venham mais ocorrer. Grandes e médios processos est?o elevando a utiliza??o dos seus processos com essa prática que diminuiu grandes quebras e reduz o custos de manuten??o.

An RCFA really helps narrow down the issue. What can even help is a pair of fresh eyes. Getting experienced personnel from other affiliates to review RCFAs are some of the best because they bring in a different perspective

Also RCA help to update the chechlists for PM. when i found a specific part is regularly causes a failure; so its better to regularly inspect it to make sure it will not effect the machine.

Um RCFA realmente ajuda a restringir o problema. O que pode até ajudar é um par de olhos frescos. Conseguir pessoal experiente de outras afiliadas para revisar os RCFAs é um dos melhores porque traz uma perspectiva diferente fico com essa opini?o

Exactly, in-depth analysis and investigation reveal the fault at its exact point, which also takes time and delays in repairs, but it is the most effective solution depending on the problem, no matter how complex it may be.

Usando de metodos tecnológicos ao nosso favor, a inteligência artificial (IA) pode desempenhar um papel significativo no apoio ao engenheiro de planta na cria??o de estratégias de reparos complexos em máquinas. Utilizando algoritmos de aprendizado de máquina, a IA pode analisar dados de sensores e históricos de opera??o para prever falhas em componentes das máquinas. Isso permite ao engenheiro antecipar e planejar reparos antes que ocorram falhas graves, reduzindo assim o tempo de inatividade n?o planejado.

Priorize os reparos que ter?o o impacto mais imediato na restaura??o da funcionalidade. é importante considerar corre??es de curto prazo e solu??es de longo prazo para evitar a recorrência.

Of course, you have to work with parts that are 100% genuine, and not with generic parts that aggravate the damage and keep the machine on standby and the expenses are multiple.

To help prevent machine malfunctions and breakdowns do a baseline assessment of the machine center. Record all pressures of any fluids and gasses, and record the temperature of the bearings and motors, time the function. Always check fluids and perform any oiling greasing etc. Record the amp draw of major electrical components. look and listen for vibrations. By doing this baseline weekly using various diagnostic tools like amp meters, heat guns, thermal cameras, gages, strobe lights, etc. you will notice when something changes and know what to watch for future repairs before a breakdown

That's right, preventive maintenance must be carried out on time to avoid possible serious damage in the future and multiple monetary expenses.

se debe realizar también, como el RCA, un archivo o LEAN PDCA para tener registrada la acción y solución de la falla o las fallas para que, cuando en el largo plazo se vuelva a tener un problema que es difícil de observar tal cual a el actual, se pueda revisar en el archivo guardado si la falla es la misma y ya evitar volver a realizar RCA y análisis o pruebas que quizás ya fueron realizadas antiguamente pero se olvidaron por no ser una falla repetitiva