Preventive Maintenance
Anatomy of a Machine Failure

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Preventive Maintenance - Software and Strategies Table of Contents

Preventive Maintenance - Anatomy of a Machine Failure

To further the discussion of Automated Maintenance Diagnostics we must first define the anatomy of a machine failure. The time between the occurrence of a failure and its full repair is divided into four periods.

• Period 1: Alarm time is the time until the alarm is detected.
• Period 2: Location time is the time until the machine failure is found.
• Period 3: Conclusion time is the time until a conclusion is drawn as how to repair or correct the failure.
• Period 4: Repair time (or Wrench Time) is the time to repair the failure.

Periods 1, 2, and 3, are the most critical because this is when the biggest damage to products and machines occur. Let’s look at the effects on each time period:

• Because the system informed the mechanic immediately with voice, text and graphics, that a failure has happened it reduced Alarm Time to almost zero.
• When the system showed the mechanic exactly which machine and part had failed in three-dimensional graphics exactly the way the machine looks in his plant it also reduced Location Time to a minimum.
• Because the mechanic was given diagnostic advice with a list of causes and possible solutions Conclusion Time significantly was quicker.
• The knowledge of how to repair the failure and part numbers was made available on a failure information screen. The experience of the maintenance staff could also be added. This helped accelerate the Repair Time.

The results are shown in the following graph: The first three periods were reduced an average of 90% and the fourth period was reduced 20% as shown in the right-hand side of the graph.

Below is the analysis of a bread line producing 7200-7800 loaves per hour.

Additionally if we consider a typical bread line has 80-100 hrs of downtime per year and we further calculate 100 hours times $5,000 per hour, times 34% savings, we have saved $170,000 for the year.

Preventive Maintenance - Software and Strategies Table of Contents

Machine Maintenance Software  -   Computerized Maintenance

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