Injection molding machines are essential tools for producing plastic parts and products. However, they also require regular maintenance to ensure optimal performance, quality, and safety. How can you develop an effective maintenance schedule for an injection molding machine? Here are some tips and best practices to follow.
Before you start planning your maintenance schedule, you should familiarize yourself with the basic components and functions of your injection molding machine. These include the clamping unit, the injection unit, the hydraulic system, the electrical system, the heating system, and the cooling system. You should also consult the manufacturer's manual and specifications for your machine model and type.
Desde mi experiencia para construir un plan de mantenimiento para cualquier equipo es importante: -Conocer sobre cada uno de los sistemas que lo componen; eléctrico, hidráulico, instrumentación, mecánico, moldes. - Tener en cuenta las recomendaciones del fabricante del equipo. -Conocer su tiempo de funcionamiento y fallas comunes.
The next step is to assess the risks and potential failures that could affect your injection molding machine. Some common factors that could cause problems are wear and tear, contamination, overheating, leaks, corrosion, and electrical faults. You should identify the most critical and vulnerable parts of your machine and prioritize them for maintenance. You should also consider the impact of downtime, quality issues, and safety hazards on your production and profitability.
Es importante elaborar un árbol de fallas con base en la información suministrada por el fabricante, adicional llevar un registro de las fallas recurrentes para aplicar un ACR (análisis de causa raíz) a cada una de ellas; esto nos puede arrojar las tareas que eliminaran o mitigaran la ocurrencia de cada falla.
There are different methods of maintenance that you can apply to your injection molding machine, depending on your needs and resources. These include preventive maintenance, predictive maintenance, corrective maintenance, and condition-based maintenance. Preventive maintenance involves performing regular inspections and tasks to prevent breakdowns and extend the machine's lifespan. Predictive maintenance uses data and sensors to monitor the machine's performance and condition and anticipate failures. Corrective maintenance involves repairing or replacing faulty or damaged parts after a failure occurs. Condition-based maintenance adjusts the maintenance frequency and intensity based on the machine's actual condition and usage.
Para máquinas de inyección se pueden aplicar varios métodos de mantenimiento: Preventivo; según la frecuencia que se establezca para todas las tareas de cada sistema. Predictivo; análisis de aceites, termografías (mecánicas, eléctricas), análisis de vibraciones.
Once you have chosen the maintenance method, you should schedule the tasks and activities that you need to perform. You should create a maintenance calendar that specifies the dates, times, durations, and frequencies of each task. You should also assign the responsibilities and roles of the maintenance team and provide them with the necessary tools and equipment. You should also communicate the maintenance schedule to the production team and coordinate with them to avoid conflicts and disruptions.
La tarea de programar las intervencciones de mantenimiento es mucho más dinámica cuando se despliegan en un software especializado de mantenimiento, ya que este nos permitirá obtener información de calidad sobre los recursos empleados (materiales, recurso humano, tiempo y parada de máquina).
Another important aspect of developing an effective maintenance schedule is recording the results and outcomes of each maintenance task. You should keep a log of the maintenance history, including the date, time, duration, type, and scope of each task, as well as the findings, actions, and recommendations. You should also document any issues, problems, or deviations that occurred during the maintenance process and how they were resolved. Recording the results will help you evaluate the effectiveness of your maintenance schedule and make adjustments if needed.
Finally, you should review and improve your maintenance schedule on a regular basis. You should analyze the data and feedback from the maintenance and production teams and measure the key performance indicators of your injection molding machine, such as uptime, output, quality, and safety. You should also compare your actual maintenance costs and benefits with your expected ones and identify any gaps or opportunities for improvement. You should also update your maintenance schedule according to any changes in your machine's condition, performance, or requirements.
Ningún plan de mantenimiento es estático; debe mantenerse en constante mejora, ya sea para incluir más actividades a ejecutar (sin perder el enfoque) o para cambiar la forma de ejecutar las actuales y reducir tiempo y dinero.