制造业的停机时间基本上被定义为”机器不运转”
任何制造商都知道,在正常情况下,机器出现故障会导致生产和收入损失减少。 未计划或计划不周的停机时间可能会干扰生产计划,并导致影响订单和生产目标的延迟。 这不是任何制造业所希望或负担得起的。
由于停机是生产损失的主要原因,并且可能导致公司损失其全部产出的20%,因此停机成本对于任何公司来说都是非常昂贵的。 生产、劳动力、更换费用、产品损失和声誉损害只是停工带来的有形和无形成本和损失中的少数几个。
此外,民意调查显示,82%的企业在过去三年中发生了意外停机事件,70%的企业并不完全了解其全部设备何时需要维修或更新。 当然,停机率会因企业而异。

预测性维护不需要太贵或太难。 即使是基本、价格合理的手续,中小企业也可以使用,从而转向预测性维修。
这可能涉及安装廉价的传感器,以识别机械或环境因素,如热量、振动和温度,可能损害或损坏机械或设备。 然后,通过将这些数据发送到中心位置,生产管理部门可以了解正在出现的问题。 因此,对昂贵、耗时的停机时间的需求大大减少。

人为错误是停机的主要原因,而不是设备或机械故障。 或者可能是人为的错误,特别是在制造业。 实际上,2017年的分析结果显示,制造业的失误率在所有行业中都最高,导致意想不到的停工。
鉴于企业如此频繁地依赖复杂而昂贵的重型设备,这并不令人惊讶。 热、噪音、人体工学等与产业卫生相关的要素可能会进一步增加设备使用难度,从而导致工人失误。

如果制造业的核心目的是”制造东西”,那么在产品不生产时,必须尽一切努力充分利用停机时间。 每个组织都必须考虑到停工时间。 然而,妥协的方式才是真正重要的。 最大限度地减少停机时间对于一个公司的盈利来说既是明智的制造,也是明智的。
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作者 Zeng Zhuojun

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