نگهداری و تعميرات بهره ور فراگير TPM

من در سایتها و وبلاگهای مختلفی مشترک هستم و در زمینه نت می توانم بگویم از کل سایتها وبلاگهای موجود در اینترنت شاید حدود 80 درصد آنها را عضو باشم و این برای من خیلی موثر وکارا بوده است ضمن اینکه همیشه دانش روز دنیا را مطلع هستم پاسخ گو برخی از سوالات و ابهامات من نیز می باشند و علاوه بر همه آنها از تجربیات دیگران بهره زیادی برده ام برای همین روی مبحث الگوبردای اعتقاد خاصی دارم بهر حال بگذریم یکی از خبرنامه های سایتهایی که مشترک هستم چند روز پشی مطلب جالبی در زمینه نت پیشگویانه رایم ارسال کرد که مفید بود این مطلب مصاحبه ای بود با یکی از فعالین و مدرسین نت پیشگویانه , چون مطالب خیلی راحت و روان بود وبعلاوه اینکه حال ترجمه هم نداشتم اصلش را برای شما قرار می دهم بهر حال کسی که طالب نت پیشگویانه باشد تا آخرش خواهد خواند !

So that's why we sat down recently with industry consultant Michael Vann.  We turned to Michael because his company (The Vann Group) has published one of the few known studies on the PdM industry.  And he's done extensive interviews and research on this sector.

Q:  Michael, can you give us a quick history of predictive maintenance?

A:  PdM is really a creation of the last fifty years.  Before World War II, maintenance wasn't even considered an important part of equipment design.  The machines were very basic compared to today.

After World War II, equipment became more complex, and more breakdowns started to occur.  That's when preventive and planned maintenance techniques emerged.

Then in the 1950's, the basic concepts of reliability mathematics were developed by statisticians at the U.S. Defense Department.

And that paved the way for the early use of PdM technologies.

In the 1960's, the aerospace and defense industries recognized the tremendous value of PdM for reducing the risk of failures.  Later, PdM technologies were adopted by the civil aviation and nuclear industries.

Finally, as the Cold War came to a close, a lot of defense and aerospace workers migrated into commercial industry, and they took their PdM knowledge with them.  Many struck out on their own and formed new companies to provide PdM services.

So it wasn't until the late 1980's and early 1990's that predictive maintenance services became mainstream.

Q:  Overall, how much do companies actually spend on industrial maintenance?

A:  In our studies, we focused specifically on the U.S. industrial market for maintaining rotating equipment.  That's estimated to be at least $200 billion a year.

Q:  How much of that is spent with maintenance contractors?

A:  There was a survey done in 2001 which indicated companies spend about one-third of their maintenance budgets with contractors.

Q:  How big is the predictive maintenance market?

A:  It's almost impossible to say exactly, because the market is so fragmented.  But it's safe to assume there's a multi-billion dollar market for PdM equipment and services.

So it's pretty sizeable - and it's been growing at double-digit rates for years.

Q:  What's causing the growth?

A:  It's simply because PdM has become more cost-effective.  The equipment is smaller, portable and more user-friendly.  The technologies are easier to use, and it's easier to interpret the information.

Plus, equipment costs have dropped, and that's reduced the barrier to getting into PdM.

So now it's easier and more cost-effective to let PdM technologies make the first assessment if an equipment problem exists or not.

Q:  Who are the biggest users of PdM services and equipment?

A:  Certainly those industries that are asset-intensive, like food & beverage, pharmaceutical, refining, petrochemicals, power generation ... the ones that own and operate a lot of valuable, expensive equipment.

Q:  What is the profile of the typical PdM service provider?

A:  As I said, it's a very fragmented industry ... there are thousands of companies involved.  But we know that most PdM service companies are small, and they are focused on a local market.  There are only a handful of companies that have a national footprint.

For example, when we interviewed thermography companies, if they had 4-5 guys that's considered a big shop.  That was a big service company.  There's only so much work that 4 guys can do.

Q:  What about revenues?

A:  It varies by technology, but we generally found that the average PdM service provider had revenues in the $1 -$2.5 million range.

Also, out of hundreds of companies we researched, very few offer more than one or two technologies.  Most are limited to one - maybe two - technologies such as vibration and infrared.

Q:  What about the PdM equipment manufacturers?

A:  Some of them offer services too - as a value-add for their customers.  But services are a very small percentage of their overall revenues.

Q:  What trends do you see in the future?

A:  I think the market is definitely going toward fully integrated solutions.  Companies are realizing that one or two technologies can't solve the majority of reliability problems that exist in their production processes.

Until recently, an integrated solution may have been a little premature.  It wasn't quite at that tipping point yet.  Now I see it becoming more mainstream.

Q:  What's going to happen to the small, local service providers?

A:  I think they'll always be around. But for large-scale corporations who want to build strategic, competitive advantages - that's tough to accomplish through dozens of local PdM service providers.  Big companies want consistent services and standards delivered across all their plants.

So that's good news for service companies who can bring a total, integrated PdM solution to the customer's sites.

Q:  What about information systems?

A:  Managers now want to see data from all the PdM technologies integrated into a single database.  Before, it wasn't easy to view information from the different technologies in a useful format.

Now decision-makers can see accurate, real-time information - the kind of information they've always dreamed about.  By drilling down into key performance trends and historical data, they can make better-informed decisions about maintenance and production.

Q:  What about finding skilled PdM technicians?

A:  There's definitely a shortage of skilled manpower - especially in remote areas where it's hard to attract workers.

That - plus the retirement of PdM professionals - is reducing the available labor pool.  Just trying to find employees is a challenge, so that's another reason why outsourcing has become popular.

The good news is the jobs being created are good jobs, like planners and schedulers, PdM technicians and analysts, reliability engineers, trainers ... people who work both with their hands and their theoretical knowledge.  These are not the typical blue-collar jobs traditionally associated with industrial maintenance.