Here's how you can minimize downtime and boost efficiency in plant operations.

Well, a mixture of PM and BM keeping in view the equipment conditions and production can save some cost as well. Use of necessary tools like vibration meters, tenso meters and physical inspections are very helpful while making decisions to change parts on a planned maintenance day.

A manutenção preventiva é parte do pilar Manutenção Planejada da filosofia TPM. Seu valor reside na concepção primária de que, um equipamento monitorado, lubrificado e limpo corretamente garante solidez e confiabilidade em sua operação. Enxergar a manutenção preventiva como uma etapa importante do planejamento produtivo no mínimo evita/reduz sustos e surpresas desagradáveis como: quebra imprevista de equipamentos, baixo rendimento, problemas qualitativos no produto ou processo e alto custos com manutenções corretivas.

Pm and cm is only part of it you but the most important thing is to have a group leader master mechanic that can handle all production schedule decision making the ability guide and troubleshooting with the team also making sure machines run safely and get the orders on time i did that all my life it works

In maintenance mix, predictive maintenance is the most proactive & efficient aspect of maintenance. it detects defects/faults before it cause equipment breakdown through robust condition based monitoring routines. Though predictive maintenance is expensive to run, it saves the company huge sum of money from unnecessary equipment failures and frequent change of spares. However, preventive maintenance is very cheap & common to use. PM is an aspect of maintenance done to sustain a maintenance standard already set up for different equipment to prevent failures. In some cases, machine failure had occurred before PM date and in this case, it will now be a breakdown maintenance.

I found PMs very helpful even for the technicians growth and understanding of the plant, and this experience and knowledge of the plant reduces downtime.

It’s very important to have streamlined processes to ensure consistent operation with continuity accordingly. Most of the technologies are used with AI tool to ensure operation with minimum variations

Lean manufacturing is an effective model to streamline processes, optimize them and improve efficiency. It helps to eliminate non value adding activities in the work stream and maximum the process. However six sigma will complement lean manufacturing model to create the magic in the value stream. Most top notch organizations had adopted these models that improved their output.

A streamlined process is a result of multiple excellent practices starting from upgraded technology to but not limited to continuous improvement in skills and motivation of employees. Continuously reducing carbon foot prints and upgrading technology for use of environment friendly chemicals could have a catalytic effect on streamlined processes.

Pessoas são a chave do sucesso em qualquer operação. Capacitar, treinar, integrar e muito mais... OUVIR, são pilares que fomentam o endomarketing, criando sentimento de propósito em todo o sistema. A frase clássica "Treino difícil, jogo fácil", reflete a essência do resultado concreto gerado por uma equipe extremamente afiada e diariamente "lapidada" pelos pilares acima definidos.

It’s all about awareness of the employees, to improve on the processes. Now a days most of the processes are technology driven and monitoring online & real-time parameters by experts

I strongly agree with this approach of increasing the competence of employees resulting in more stable plant operations and strong business development as everyone has its own eyes and brain. It's only the matter of time and skill which get multiplied with workforce and starts delivering magically.

Training is very necessary as it improves skill of employees, empowers them with right knowledge that enables them to make superior business decision that will improve productivity. Machines needs human interventions and operation to function effectively to deliver result. Even in the event of equipment breakdown, it`s high skilled employees that will be able to fix them. So training cannot be over emphasized in any organization.

I have found that integrating new technology like APC controls are helpful but are limited as there is always a need for continuous analysis and managing requirements which come up with day to challenges and needs. An integrated technological approach in collaboration of a highly competent team with an open and innovative mind set can meet day to day challenges.

A aplicação do Kaizen na planta é um excelente ponto de partida para engajar todos os níveis da equipe em um processo de melhoria contínua. No entanto, é crucial que existam sistemas de feedback bem estruturados que permitam capturar e implementar sugestões de maneira eficiente. Utilizar indicadores de performance e técnicas de análise de falhas, como FMEA (Failure Modes and Effects Analysis) ou Análise de Causa Raiz, pode ajudar a identificar impeditivos e oportunidades de melhoria. A integração de tecnologia, como sistemas de monitoramento, também pode fornecer insights valiosos, permitindo que as equipes antecipem problemas antes mesmo que se tornem falhas críticas, reduzindo assim o tempo de inatividade.

``Ideas rules the world`` Every process and technology needs to undergo changes with time. For this changes to happen, it takes some sort of ideas to bring them together. Countinuous improvement must be continuous as it implies. Organizations must encourage her employees to generate ideas that will improve their processes so they can continue to compete with their rivals. A platform should be created to collate these ideas and follow up tracked for its implementation. ``Every idea remains a dream until it`s worked up to transform it into reality that will bring the improvement``

As history reveals ignoring small improvement details can lead to catastrophic damages or even close out of the business assets. That's why philosophy of continuous improvement is an essential element for sustaining safe and reliable business operation.

Standby and backup/alternate equipment/process also plays a key role in reducing downtime. It also helps out in preventive maintenance or schedule maintenance and is a case of emergencies. Of course the capital cost is more but it reduces the running cost effectively, resulting in increasing ROE.