You're facing unexpected machine breakdowns. How can you maintain product quality?

Preventative and predictive maintenance is key in minimising breakdowns,ensure genuine or OEM parts and spares are used in repair work,communication between shifts should be smooth,precise and transparent.

A mi me a sido útil la planificación del mantenimiento ya que al tener una frecuencia del trabajo y saber el tiempo de vida útil para evitar las paras y da?os repentinos.. Tener stock de repuestos y equipos predictivos para el diagnóstico..

The crucial point for proactive maintenance is the efficiency in data collection and communication among the maintenance team in order to have effective management.

Best practice recommends Implementing solid FMEA and or FMECA - this helps in addressing core and key maintenance issues on equipment.

Buenas tardes a todos, en mi caso es tener un plan de contigencia cuando la avería ocurra. Si no lo tienen y la avería produce defectos agarre el liderazgo y coordine. Avise a producción y que ellos colaboren con un plan si la avería tardará horas en repararse. Con su equipo de mantenimiento diagnostique y de una respuesta; horas de reparación, cambio de máquina, uso de diferentes metodos de verificación de calidad. Proceda hacer su reparación lo mas rapido posible, si requiere de servicio externo tenga en cuenta que posible el costo del proveedor será elevado pero impactará mas en la producción.

The biggest set back in most of the places I have worked is communication and training. A well trained team is very beneficial in all aspects of a company.

I think that one of the biggest challenges that equipment reliability faces is the lack of understanding of those that operate equipment knowing and understanding the basics of how their equipment is supposed to function. The same could be said about those who maintain the equipment not knowing what food or normal operation looks like. I had a pumping system that I was routinely failing and as part of the rca we observed the operation of the equipment. It was discovered that the start up procedure that had been in place was to start the pump with an empty line and then open the suction and discharge valves causing premature equipment failure. Changing this one practice ended the almost weekly pump failures.

Staff training is essential for effectively managing machine breakdowns and ensuring product quality. It is crucial that the team is well-versed in operational procedures, troubleshooting techniques, and emergency response protocols. Cross-training employees on different machines also increases flexibility, enabling quicker responses when breakdowns occur. By equipping the staff with the necessary knowledge and skills, the impact on product quality is minimized, and production continuity is maintained.

I believe a good combination of experience and computerized controls make for a great quality control. Quality control in my experience is lacking in a lot of industries.

Maintainance and servicing of the machine will prevent break down of the machine and a well serviced machine is as good as new.

Rigorous quality control measures are essential to maintaining product quality during machine breakdowns. Implementing real-time monitoring systems allows immediate detection of deviations in product specifications, enabling quick corrective actions before producing too many defective products. Additionally, a strong quality assurance process, including regular inspections and testing, ensures that even if production equipment fails, product quality is not compromised.

Process redundancy in manufacturing is crucial for mitigating the impact of machine breakdowns. Designing production lines so that if one machine fails, others can take over without significant loss in productivity or quality is key. This may involve investing in multipurpose machines or setting up parallel lines that can be activated when needed. By creating a flexible manufacturing environment, you can ensure product quality is maintained even when facing equipment challenges.

Adopting a culture of continuous improvement is essential for enhancing your ability to maintain product quality during machine breakdowns. Utilizing methodologies such as Six Sigma or lean manufacturing can help analyze breakdown incidents and develop strategies to prevent future occurrences. Encouraging feedback from your team allows for the identification of weaknesses in processes and equipment. By continuously refining operations, you can build resilience against machine failures and ensure product quality is upheld.