Operations & Maintenance
Operations & Maintenance (O&M) means the functions, duties and labor associated with the daily operations and normal repairs, replacement of parts and structural components, and other activities needed to preserve an asset so that it continues to provide acceptable services and achieves its expected life.
Why (O&M) is important?
The importance of an effective maintenance program cannot be overlooked because it plays such an important role in the effectiveness of Lean manufacturing. As in personal health care insurance, maintenance may be considered the heath care of our manufacturing machines and equipment. It is required to effectively reduce waste and run an efficient, continuous manufacturing operation, business, or service operation. The cost of regular maintenance is very small when it is compared to the cost of a major breakdown at which time there is no production.
A machine’s breakdown true cost is sometimes difficult to measure. A recent survey showed that the cost for a machine breakdown is more than just the maintenance labor and materials to make the repair. A recent survey showed the actual cost for a breakdown between four to fifteen times the maintenance costs. When the breakdown causes production to stop, the costs are very high because no parts are being produced.
Purpose of Operations & Maintenance
The main purpose of regular maintenance is to ensure that all equipment required for production is operating at 100% efficiency at all times. Through short daily inspections, cleaning, lubricating, and making minor adjustments, minor problems can be detected and corrected before they become a major problem that can shut down a production line.
A good maintenance program requires company-wide participation and support by everyone ranging from the top executive to the shop floor personnel.
Benefits of Motor Maintenance
Motors need maintenance regularly in order to avoid failure and prolong their lifespan. Generally speaking, motors and motor parts should be maintained and tested at least every 6 months. Only then is it possible to maintain a motor’s life and its efficiency.
Electric motors are efficient, powerful, and effective machines, but they’re not immune to occasional malfunctions, gradual deterioration, and minor hiccups. That’s why electric motors need regular maintenance to help them work up to their full potential. And by choosing to put a predictive electric motor maintenance program in place, organizations can address minor, preventable issues that, if untreated, could lead to bigger disasters.
Issues such as excessive heat and broken bearings can affect a motor over time. But catching issues like these early on with a predictive electric motor maintenance plan can extend the service life of a machine and reduce the chances of catastrophic motor failure. A predictive maintenance plan can also minimize safety hazards to your employees, drive profit, enhance productivity, and reduce unnecessary expenses in the workplace.
Five major benefit you will get if you have proper maintenance:
• Address Issues Before They Become Urgent
• Increase Equipment Lifespan
• Improve Motor Performance
• Prevent Costly Downtime
• Save Money and Energy
Benefits of VFD Maintenance
Variable Frequency Motor Drives (VFD’s) convert electrical energy into mechanical energy, offering controls to regulate speed and torque. In fact, a properly functioning variable frequency drive can delivery up to 55% in energy cost savings.
Regular preventative maintenance helps all electronics run longer and provide more consistent performance. VFDs benefit from regular maintenance, especially if they have open side vents, that may allow foreign objects or moisture to contaminate the inside of the housing. This, in turn, minimizes replacement costs and critical failures that lead to unexpected downtime.
Maintaining the VFDs also allows them to perform with greater control and the capacity to meet different load requirements. Depending on your state and locality, your energy provider might also provide rebates for using and regularly maintaining variable frequency drives.
Unfortunately, many businesses put off motor drive maintenance until a system experiences a catastrophic failure. The resulting costs from a complete motor replacement, as well as lost profits from production downtime during installation, are often much more expensive than the price of routine maintenance and repair would have been. If you experience electric motor drive problems, take care of them early to avoid costly repair services.