Problems of maintenance of equipment in a crisis

As a result of the current economic crisis, many Russian industries were in very bad condition. Particularly hard hit by the crisis the industrial sphere. For example, the automakers are suffering huge losses and significantly reduce the amount of output due to the sharp fall in demand for it. For example, the only domestic auto industry has made in the first quarter of this year car is almost 3 times lower (123 000 units) over the same period in 2008. In such difficult circumstances questions of economy, different kinds of resources and the use of production reserves become a priority. One of the "patients" places of Russian industrial enterprises is maintenance and repair of equipment. Positive changes in the economy in recent years has not solved the problem replacing obsolete assets. Now a very high percentage of equipment with high rates of physical deterioration, as well as those machines that have long since exhausted its resources. But new equipment for improper use and will not be able to function effectively, will often break down and idle. A downtime - it's an additional loss of time and money, which is unacceptable in a crisis. Thus, maintenance and repair of equipment, especially for businesses with high-volume mass production and plays a critical role in ensuring the efficient production process and save resources. Currently, we can identify the following problems in this area, existing in Russian enterprises: a high proportion of heavily-worn equipment that requires frequent repairs, lack of funds for renovation / modernization of equipment, inappropriate organization of maintenance services, and equipment repair (MRO) and the use of a legacy system maintenance and repair; underutilization of the labor potential of professionals and workers, the need to reduce the cost of repair and maintenance of equipment in an economic crisis. To solve them, or minimize the expedient seems to hold events. Considering the problem of obsolete equipment and lack of money to replace it, we note that in times of crisis the volume of industrial production are falling, so some of the most worn-out equipment it is possible to retire - mothball or sell. The funds received (including from maintenance savings, by reducing the stock of equipment and introduction of new systems, equipment maintenance), in conjunction with other funding sources (state support, bank loans and direct investments), depending on financial and technical condition of the company may be sent for renewal of fixed assets. The irrational organization of maintenance services and the use of a legacy system maintenance and repair of equipment - one of the most serious problems of our medium and large enterprises. Currently, most of them used the classic system obligingly-scheduled repairs (PPR), which was developed in the USSR in the mid-50s of the twentieth century. The main features of a system outage is planned nature and prevention focus. Planned nature involves early identification of the composition, volume and frequency of servicing and repair work. Preventive orientation includes a service and repair operations before the failure. The system provides for the supply outage of the unit in for repair, after he has completed a certain number of hours. The basis for the development of a system outage statistics were obtained in Doha failure analysis equipment [1]. Currently the system is hopelessly outdated. Among its shortcomings mention ignoring the actual conditions of the equipment, materials and spare parts, outdated regulations and inaccurate evidence significant deviations from the planned operation of the equipment. So one of the machine-building enterprises use standard system outage resulted in the fact that no more than 28-30% of the equipment withstand regulatory overhaul, a 15-18% increase in equipment downtime for repair, as well as increased rates of physical wear and tear on the 15 - 18% [1]. Alas, but to completely abandon a system outage is not possible due to the requirements of Russian law. In accordance with the regulations, a system outage is a major tool to ensure safe and reliable operation of equipment. For non-related requirements, and regulatory and technical documentation may result in certain penalties up to suspension of production. Under these conditions, drawing particular attention to another type of system maintenance and repair, providing maintenance of the equipment on its actual state, but with preservation of preventive maintenance. The most promising modern system of the equipment is now a system of universal service equipment, known in English as a reduction of TPM (Total Productive Maintenance). TPM system has been developed in Japan in the late 60's and 70's in the firm "Nippon Dance" - the supplier of electrical equipment for the company "Toyota" as a method of improving the efficiency of equipment and equipment maintenance is a system in its actual state. Its development is closely linked with the development of the production system by "Toyota." TPM system has remained a secret development until 1980, when it published its first description in English. In January 1998 the system was introduced TRM3-improvement and expansion of the Australian version of the third generation of TPM [3]. The system includes a set of methods designed to ensure that each machine was kept in serviceable condition, and the production is never interrupted. A characteristic feature of this system is the continuous monitoring and acoustic test equipment for early detection of defects and prevent its failure. Of particular importance is the joint work of equipment operators and maintenance specialists services that must work together to provide increased reliability. Since the operators are always near the equipment so that they first determine the smallest deviation from the proper operation and play a critical role in its primary care, prevention and diagnosis of faults. As a result, can improve the efficiency of the equipment and its performance, significantly reduce the cost of its maintenance and repairs, reduce time to conversion, to reduce accidents and injuries at work. As an example of real improvements in the maintenance and repair of equipment in the implementation of TPM, we note the following: reducing the number of random failures and accidents at 10-250 times, increasing the load of equipment - by 1.5 times, reducing the release of the cases of defective products - up to 10 times , reduction of production costs - up to 30% [3]. Note also that the TPM can best use the available capacity of professionals and workers, providing for measures to encourage active innovation, continuous improvement of staff, improving his skills. It is the gradual introduction of such a competent maintenance system at Russian enterprises can help solve immediate problems highlighted earlier in this area. Bibliography: 1. Mityushin VS MYTH 2: Work on the maintenance and repair of equipment (MRO) is impossible to plan / VS Mityushin / / Compass Industrial Restructuring - № 3 - 2004. 2. Kennedy R. Interaction of 5S and TPM system TRM3 / R. Kennedy, L. Matza. / / Standards and Quality - 2004. - № 8. 3. Pshennikov V. Quality through TRM, or the marginal efficiency of industrial equipment. The electronic edition - http://tpm-centre.ru, 2006.