Was ist industrielle Instandhaltung? Definition, Strategien, Software

Was ist industrielle Instandhaltung?

Industrial maintenance is the practice of maintaining industrial machines and preventing breakdowns. Industrial maintenance involves regular upkeep, emergency repairs, and long-term preventive and predictive maintenance strategies.

Ziel der industriellen Instandhaltung ist es, Ausfallzeiten zu reduzieren, die Langlebigkeit von Anlagen zu erhöhen und die Zuverlässigkeit der Anlagen insgesamt zu verbessern. Schlecht laufende Maschinen verbrauchen übermäßig viel Energie, führen zu Materialverschwendung und verursachen kostspielige Ausfallzeiten. Die wichtige Praxis der industriellen Instandhaltung stellt sicher, dass Produktionsanlagen, Fabriken und andere industrielle Einrichtungen effizient, sicher und mit minimalen Ausfallzeiten arbeiten.

When industrial maintenance teams keep assets running as designed, it helps maximize safety, output, and uptime, boosting the bottom line. Activities like the servicing, repairing, and replacing machine components — from small bearings to entire compressor units — in an industrial setting fall under the umbrella of industrial maintenance.

Die industrielle Instandhaltung umfasst eine Reihe von Aktivitäten, darunter regelmäßige Inspektionen, vorbeugende Instandhaltung, korrektive Reparaturen und den Einsatz fortschrittlicher Überwachungstechnologien zur Vorhersage und Vermeidung von Ausfällen.

Benefits of Industrial Maintenance

Die industrielle Instandhaltung ist aus mehreren Gründen wichtig:

• Improves operational efficiency: Regular maintenance helps ensure that equipment operates at peak performance, reducing the likelihood of unexpected breakdowns that can disrupt production schedules.

• Increase safety: Properly maintained equipment is less likely to fail in ways that could harm workers, making industrial equipment maintenance a key component of workplace safety.

• Realizes cost savings: By preventing major breakdowns and extending equipment lifespans, industrial maintenance can save companies significant amounts of money in the long run.

• Boosts regulatory compliance: Many industries are subject to strict regulations regarding equipment maintenance. Meeting these standards is essential to avoid fines and legal issues.

Häufige Berufe in der industriellen Instandhaltung und Arten von Arbeitnehmern

Industrial maintenance requires a diverse workforce with various skills and expertise. Generally speaking, industrial maintenance technicians need to be skilled in performing hands-on work, following directions, and be familiar with a work order management system.

Im Folgenden werden einige gängige Berufe und Arten von Arbeitnehmern vorgestellt, die in der industriellen Instandhaltung tätig sind:

Maintenance technicians

Industrial maintenance technicians perform routine inspections, repairs, and industrial equipment servicing. Also called industrial maintenance mechanics, they diagnose issues, replace faulty components, and ensure machinery operates smoothly.

• Skills: Technical knowledge of machinery, problem-solving abilities, and proficiency in using various tools and equipment.

Maintenance engineers

Maintenance engineers develop and oversee maintenance strategies to ensure equipment reliability. Employees in these roles analyze equipment performance data, recommend improvements, and implement preventive maintenance plans.

• Qualifikationen: Technisches Fachwissen, analytische Fähigkeiten und Erfahrung mit Wartungsplanungssoftware.

Reliability engineers

This role focuses on improving the long-term reliability of equipment. Reliability engineers study failure data, identify root causes, and develop strategies to enhance equipment reliability and minimize downtime.

• Skills: Strong analytical abilities, knowledge of reliability engineering principles, and experience with predictive maintenance technologies.

Maintenance managers

Industrial maintenance managers oversee the entire maintenance department, ensuring that all activities are carried out efficiently and effectively. They manage resources, coordinate schedules, and ensure compliance with safety and regulatory standards.

• Skills: Leadership and management skills, strategic planning, and knowledge of maintenance best practices.

Condition monitoring technicians

Condition monitoring technicians use advanced monitoring tools and industrial maintenance technology to assess the condition of equipment in real-time. They collect and analyze data to predict potential failures and recommend timely interventions so failure can be avoided.

• Fertigkeiten: Beherrschung von Überwachungstechnologien, Fähigkeiten zur Datenanalyse und Liebe zum Detail.

Planners and schedulers

Planners and schedulers are responsible for planning and scheduling maintenance activities. They ensure that maintenance tasks are carried out at the right time and with minimal disruption to operations.

• Fertigkeiten: Organisations- und Planungsfähigkeiten, Erfahrung mit Planungssoftware und die Fähigkeit, Wartungsanforderungen mit Produktionsanforderungen in Einklang zu bringen.

Jede Rolle in einem industriellen Wartungsteam ist entscheidend für einen effizienten und zuverlässigen Betrieb der Anlagen. Durch die Zusammenarbeit dieser Fachleute können unerwartete Ausfälle verhindert, Wartungspläne optimiert und die Gesamtleistung der Anlagen verbessert werden.

Für Wartungsarbeiten, die spezielle Kenntnisse oder Werkzeuge erfordern, muss Ihr Team möglicherweise auch auf Auftragnehmer zurückgreifen. Einige Arten von Gerätekalibrierungen, Vibrationsanalysen, elektrische Reparaturen, Reparaturen von Robotern oder Automatisierungsanlagen und die Wartung von Aufzügen sind beispielsweise Aufgaben, die an einen Spezialisten vergeben werden müssen.

Sometimes, it can be difficult to find individuals who can perform the tasks your organization needs. Cross-training your existing staff to teach new skills can help combat these limitations. Using specialized software, like a computerized maintenance management system (CMMS), can also help provide your team with checklists, guidelines, and necessary steps to complete their tasks, making it easier for team members to perform the maintenance your organization needs.

Welche Branchen nutzen industrielle Instandhaltung?

Die industrielle Instandhaltung ist ein wichtiger Bestandteil zahlreicher Industriezweige, die jeweils spezifische Anforderungen und Herausforderungen haben. Hier sind einige der wichtigsten Branchen, die sich stark auf die industrielle Instandhaltung verlassen:

Herstellung

• Überblick: Die Produktion von Waren erfolgt mit Hilfe von Maschinen und Arbeitskräften. Die Wartung ist entscheidend, um eine kontinuierliche Produktion zu gewährleisten und kostspielige Ausfallzeiten zu vermeiden.
• Key maintenance activities: Regular inspections, preventive maintenance, condition monitoring, and predictive maintenance to keep production lines running smoothly.

Energy and Utilities

• Overview: Includes power generation, water treatment, and utility services. Industrial plant maintenance ensures reliable service delivery and compliance with safety regulations.
• Key maintenance activities: Scheduled inspections, real-time monitoring, and advanced diagnostics to maintain infrastructure and prevent service interruptions.

Öl und Gas

• Overview: Involves exploration, extraction, refining, and distribution of oil and gas. Factory maintenance is essential to ensure safe and efficient operations.
• Key maintenance activities: Corrosion control, regular inspections, condition-based maintenance, and the use of predictive analytics to prevent failures.

Transportation and Logistics

• Überblick: Umfasst die Beförderung von Waren und Personen. Die Instandhaltung gewährleistet die Zuverlässigkeit und Sicherheit von Fahrzeugen, Flugzeugen, Schiffen und Infrastruktur.
• Key maintenance activities: Routine servicing, component replacements, safety inspections, and adherence to regulatory standards.

Essen und Trinken

• Overview: Involves the processing and packaging of food and beverages. Maintenance is critical to ensure product quality, safety, and compliance with hygiene standards.
• Key maintenance activities: Cleaning, calibration, lubrication, and regular inspections to maintain equipment and prevent contamination.

Pharmazeutika

• Überblick: Die Herstellung von Arzneimitteln und Medizinprodukten. Die Wartung gewährleistet die Präzision und Zuverlässigkeit der Produktionsanlagen.
• Key maintenance activities: Preventive maintenance, regular inspections, calibration, and strict adherence to regulatory requirements to ensure product quality and safety.

Bergbau

• Überblick: Die Gewinnung von Mineralien und Rohstoffen. Die Instandhaltung ist wichtig, um die Zuverlässigkeit und Effizienz von schweren Maschinen und Anlagen zu gewährleisten.
• Key maintenance activities: Regular servicing, component replacements, system checks, and the use of advanced diagnostics to prevent breakdowns.

Einrichtungen des Gesundheitswesens

• Overview: Involves maintaining facilities for patient care, such as hospitals, assisted living facilities, and hospice centers. Maintenance is needed to ensure medical equipment is functioning well and the entire facility is safe and hygienic for both employees and patients.
• Key maintenance activities: Cleaning, preventive maintenance for medical equipment and facility equipment like HVAC systems and plumbing, regular inspections, adherence to compliance requirements, and safety checks for critical equipment like fire extinguishers and exit signs.

Hospitality-Einrichtungen

• Overview: Involves maintenance for hotels, resorts, apartment complexes, and similar facilities. Maintenance is critical for ensuring guest safety and satisfaction, as well as compliance with government regulations.
• Key maintenance activities: Inspections and cleaning of HVAC and plumbing systems, addressing immediate needs like electrical outages or broken appliances, cleaning, regular inspection of safety equipment such as fire extinguishers, inspecting and repairing security systems. Also ensuring that common areas like pools, entryways, and fitness centers are clean and equipment is operational.

Beispiele für industrielle Instandhaltung

Industrial maintenance covers almost any task that needs to be performed in a plant. Here are a few examples of the types of maintenance included in industrial plant maintenance:

Wartung von Förderbändern

Förderbänder sind kritische Komponenten in vielen industriellen Prozessen, insbesondere in der Fertigung und im Materialtransport. Die routinemäßige Wartung von Förderbändern umfasst mehrere wichtige Aufgaben:

• Inspektion: Regelmäßige Überprüfung auf Verschleiß, Fehlausrichtung und Beschädigung des Riemens und seiner Komponenten.
• Schmierung: Sicherstellen, dass Lager, Rollen und andere bewegliche Teile ordnungsgemäß geschmiert sind, um Reibung und Verschleiß zu verringern.
• Belt tensioning: Adjusting the tension to prevent slippage and ensure smooth operation. Too much or too little tension can cause operational issues and accelerate wear.

HVAC System Wartung

Heizungs-, Lüftungs- und Klimaanlagen (HVAC-Systeme) sind für die Aufrechterhaltung einer kontrollierten Umgebung in Industrieanlagen unerlässlich. Zu den üblichen Wartungsaufgaben für HLK-Systeme gehören:

• Filter replacement: Regularly replacing air filters to maintain air quality and system efficiency.
• Coil cleaning: Cleaning the evaporator and condenser coils to improve heat exchange efficiency and prevent system overload.
• Inspection and calibration: Checking thermostats and control systems to ensure they are functioning correctly and calibrating them as needed to maintain desired temperature and humidity levels.

Wartung von Pumpen und Motoren

Pumpen und Motoren sind in vielen industriellen Anwendungen zu finden, von der Wasserversorgung bis zur Prozesssteuerung. Zu den Wartungsaufgaben für diese Komponenten gehören häufig:

• Alignment checks: Verifying that motors and pumps are properly aligned to avoid excessive vibration and wear.
• Schmierung: Regelmäßiges Schmieren der Lager und anderer beweglicher Teile, um die Reibung zu minimieren und Überhitzung zu vermeiden.
• Performance testing: Monitoring and testing the performance of pumps and motors to detect issues such as reduced flow rates or abnormal noises, indicating potential problems.

Wartung des Verdichtersystems

Kompressorsysteme kommen in vielen industriellen Prozessen zum Einsatz, z. B. beim Antrieb von Druckluftwerkzeugen und beim Transport von Druckgasen. Zu den Wartungsaufgaben für Kompressorsysteme können gehören:

• Filter checks and replacement: Consistently checking and replacing air filters to ensure the gas can move through the system and that any pollutants or contaminants have been removed.
• Lubrication: Regularly lubricating bearings, gears, and other components to help the compressor run smoothly and avoid unnecessary wear on components.
• Regular inspections: There are many types of compressors, but they all need to be inspected for leaks, proper lubricant levels, contamination, and other factors based on the compressor’s needs and maintenance timeline.

Wartung von Fräsmaschinen

Fräsmaschinen verwenden rotierende Fräser, um Material von Werkstücken zu entfernen. Sie werden in einer Vielzahl von Branchen eingesetzt, z. B. in der Automobilindustrie, in der Herstellung medizinischer Geräte, in der Landwirtschaft und in vielen anderen Bereichen. Die Wartung von Fräsmaschinen umfasst:

• Cleaning: Removing dust, debris, and residue buildup to ensure the milling machine can perform as expected.
• Lubrication: Regularly lubricating moving parts like slides, gears, and bearings according to the manufacturer’s specifications to ensure smooth operation and reduced wear and tear on components.
• Calibration and alignment: Performing regular calibration and alignment to help the machine maintain its accuracy and avoid wasted materials from improper machining.

This is just a small example of the tasks included in industrial maintenance. Troubleshooting equipment problems, scheduling future maintenance tasks, performing regular inspections, and spare parts inventory management are all included in industrial maintenance.

What is Industrial Equipment Maintenance?

Industrial equipment maintenance is the practice of maintaining, repairing, and managing machinery and systems used in manufacturing and other industrial applications. It’s focused on equipment only, while industrial maintenance can be used to describe maintenance across a factory or organization.

Industrial Maintenance Strategies

Industriemaschinen, von gewöhnlichen Anlagen wie Motoren bis hin zu komplexen Systemen wie Windturbinen, durchlaufen einen Lebenszyklus, der von der Installation über den Betrieb bis hin zum Ende der Lebensdauer oder einem Ausfall reicht. Die Instandhaltung ist der Schlüssel zur Optimierung der Lebensdauer von Anlagen - sie sorgt dafür, dass diese so lange wie möglich effektiv arbeiten.

We often think of maintenance as an emergency response to faults, failures, or total breakdowns, and it’s true that industrial maintenance work is often reactive firefighting. Maintenance is vital to employee safety, like when an ammonia compressor fails and toxic gas leaks. It’s also essential for compliance with key regulations from OSHA to the FDA and IATF. And of course, maintenance keeps production going and revenue flowing.

Doch wenn Sie sich auf reaktive oder ausfallbedingte Wartung als einzige Strategie verlassen, kann dies katastrophale Folgen haben. Ein rein reaktiver Ansatz vergeudet Zeit, Arbeit und Geld und verlangsamt die Produktion.

Vorausschauende Wartungsstrategien können reaktive Strategien ergänzen - und zu besser verwalteten Anlagen führen, die länger in Betrieb bleiben. Instandhaltungs- und Zuverlässigkeitsteams können die Leistung der vorbeugenden, zustandsorientierten und vorausschauenden Instandhaltung nutzen, um die Betriebszeit zu maximieren. Hier sehen Sie, wie verschiedene Instandhaltungsstrategien im Vergleich aussehen:

Reaktive Wartung

Reactive maintenance is performed in response to machine issues, ranging from minor faults to major failures. Also known as “run-to-failure” maintenance, reactive maintenance is only performed when problems arise. A reactive approach is ideal for easily-replaceable parts like lightbulbs, but can be problematic for complex and critical industrial machines.

Breakdown Maintenance

Breakdown maintenance is a strategy in which workers wait until a machine fully breaks down or is out of operation before performing maintenance work. A breakdown maintenance strategy can make sense for non-critical assets, but is dangerous and costly when applied to production-critical machines.

Vorbeugende Wartung

Preventive maintenance (PM) involves planning regular maintenance to prevent faults and failures. Preventive maintenance is scheduled at regular time intervals or equipment usage intervals. A PM approach to industrial maintenance reduces the risk of asset downtime and is important for essential assets.

Condition-Based Maintenance

Condition-based maintenance (CBM) is work done in response to asset condition data, like vibration or temperature levels, that gives insight into machine health. CBM is vital for sophisticated machines that need to be monitored to know when maintenance is needed.

Vorausschauende Wartung

Predictive maintenance (PdM) is maintenance work performed in advance of a breakdown that is informed by predictive data, like detailed vibration data captured by wireless sensors. Predictive maintenance is a powerful tool for maxing the uptime and strengthening the reliability of your most critical assets.

Reliability-Centered Maintenance

Reliability-centered maintenance (RCM) is a framework that focuses on the big picture: what maintenance strategy is best for each asset or type of asset to achieve cost-effective uptime? A reliability-centered strategy calls on the best approach for the job, from run-to-failure maintenance to preventive maintenance. Reliability-centered maintenance often involves asset criticality assessment (ACA), failure modes and effects analysis (FMEA), and fault tree analysis (FTA) as methods to analyze assets and determine the ideal game plan.

How to Improve Your Industrial Maintenance Strategy

With so many different types of maintenance, it can be challenging to figure out a maintenance strategy that will work for the whole factory. You can’t just let everything run until it completely stops working. But at the same time, it doesn’t make sense to perform preventive maintenance on every piece of equipment.

Instead, take these steps to improve your industrial maintenance strategy, whether you’re building a strategy from the ground up or just working to improve an existing strategy.

1. Assess your Current Strategy

Review asset performance, failure history, response times, and maintenance costs. What’s working? What isn’t?

2. Define Clear Maintenance Goals

Align your factory maintenance goals with your business objectives. These could include reducing downtime, extending asset lifespan, improving safety, or cutting costs.

3. Classify and Prioritize Assets

Use a criticality analysis to prioritize assets based on factors like production impact, safety concerns, and costs. This can help you direct maintenance resources where they will have the biggest impact on your facility.

4. Choose the Right Maintenance Approach for Each Asset

Now you’re ready to assign maintenance strategies to your assets, using the strategy that makes the most sense for each one.

5. Standardize Procedures

Even the best industrial maintenance strategy can fail if the people implementing it aren’t consistent. Standard procedures make sure your team performs tasks the same way, every time.

6. Collect Data

Track data such as mean time between failures (MTBF), unplanned downtime hours, and overall equipment effectiveness so you can see where your new strategy is working and where it needs refining.

7. Review, Refine, Repeat

Regularly review the data you’ve collected to see where maintenance strategies may need to be adjusted or changed. Certain assets may need preventive maintenance more frequently than you initially planned, for example. These changes keep your facility on the right track and enable continuous improvement.

The Rise of New Technology in Industrial Maintenance

Industrial maintenance practices are evolving quickly. New technology paves the way for improvements in industrial maintenance strategies and introduces new skills industrial maintenance technicians can use to improve maintenance practices across facilities.

1. IoT Sensors & Smart Devices: These sensors collect real-time data about assets, giving industrial technicians information about asset health so they can perform condition-based maintenance and predictive maintenance, resulting in more effective maintenance practices.

1. Remote Condition Monitoring: Instead of having to physically visit a machine, technicians can use sensors and connected platforms to check machine status in real time, saving valuable time and letting industrial maintenance technicians focus on repairs rather than machine monitoring.

1. AI and Machine Learning: Historical and real-time data from sensors can be analyzed with AI to detect patterns and predict failures, and industrial maintenance technology can even make recommendations about maintenance tasks. Technicians can use this data to perform repairs and prevent unplanned downtime.

Cloud-based industrial maintenance software harnesses the power of each of these technologies and provides a centralized location for asset data, work orders, inventory, and reporting in a single platform.

Warum eine Software für die industrielle Instandhaltung?

Instandhaltungsteams in der Industrie benötigen Instandhaltungssoftware für die Verwaltung, Planung und Ausführung einer erfolgreichen Strategie.

Maintenance software serves as a command center for work orders, asset management, spare parts inventory, maintenance KPI reporting, and much more. It can store standard operating procedures and maintenance history, providing key information for future maintenance decisions. Leading maintenance management software also offer mobile apps, condition monitoring, integrations with key business systems, and global, multi-site capabilities.

Common software types include computerized maintenance management systems (CMMS) and enterprise asset management (EAM) systems, which often overlap.

Ein CMMS oder EAM ermöglicht es industriellen Wartungsteams, Zeit zu sparen, ihre Arbeit zu vereinfachen, Kosten zu senken, Ausfallzeiten zu vermeiden und die Zuverlässigkeit der Anlagen insgesamt zu erhöhen.

Instandhaltungsteams in der Industrie verwenden oft eine Kombination von Instandhaltungsstrategien in ihrer Anlage, und ein CMMS kann jede dieser Strategien verbessern. Hier sind einige konkrete Möglichkeiten, wie ein CMMS verschiedene Ansätze unterstützen kann:

• Reactive maintenance: When an asset fails or isn’t performing as expected, team members can:
  • Create a maintenance work order
  • Assign a technician
  • Upload key details about the problem.
  • Work order and asset history in the CMMS give the technician vital tools to help troubleshoot and correct the problem as quickly as possible, minimizing downtime.

• Preventive maintenance: Managers can:
  • Create and assign work orders for regular preventive maintenance tasks like inspections, filter changes, lubrication, and cleaning.
  • These tasks can also be automated to occur regularly, ensuring teams stay on top of vital PMs over time.

• Predictive maintenance: When wireless sensors receive data that indicates the asset is operating outside of its ideal conditions, a CMMS can:
  • Notify users of potential faults
  • Create alarms and work orders automatically
  • Ensure developing issues are fixedas quickly as possible.

• Reliability-centered maintenance: Companies implementing an RCM strategy can use a CMMS to:
  • Document the maintenance methods, checklists, and other key data for each asset
  • Use KPIs and data from the CMMS to continually improve their RCM model and ensure every asset receives the correct maintenance at the right time.
• Graphic?

Wenn Teams Daten über den Zustand von Anlagen verfolgen, Trends ermitteln und analysieren, können sie bessere Entscheidungen treffen, Prioritäten bei der Planung und den Ausgaben setzen und Kosten senken.

Durch einen besseren Einblick in die industriellen Wartungsaktivitäten können die Teams Trends erkennen, sich an veränderte Prioritäten anpassen und ihre Kommunikation und Prozesse verbessern. Die Zentralisierung der gesamten Dokumentation - von Verträgen bis hin zu Handbüchern - vereinfacht den Compliance-Prozess und stellt sicher, dass die Mitglieder des Wartungsteams jederzeit und überall sicher auf die benötigten Informationen zugreifen können.

To make the most of your industrial maintenance program, you need to define your maintenance management goals and targets. A CMMS like eMaint can track metrics, generate reports, and deliver insights you can use to reach your goals.

See how eMaint allows you to manage assets, create and assign work orders, view live asset status, manage inventory, reduce costs, and more with a CMMS demo walkthrough.