Paper is an integral part of our daily lives, with applications in printing (newspapers, magazines, catalogs, books, posters etc), hygiene paper products (tissue, napkins, towels etc), packaging (board, liners, wrapping), and as specialty papers (cigarette, wall/decorative paper).
The user of printing machines and any other operating systems, expects the machine or system to stand a heavy-duty use during a given period. This period is not constant. It depends on the construction, the nature of use, the mode of operation and the quality of maintenance as well. Nevertheless, the analysis of these technical systems, the profound knowledge of the characteristics of building elements and the operating indices are essential to establish an adequate operational and maintenance concept.
At present, according to the results of a survey the major cause (46%) of maintenance events is the unexpected breakdown.
Therefore, the knowledge about unexpected breakdowns, as a phenomenon, is extremely important for the maintenance management.
Many studies indicate that condition monitoring of paper and printing machines significantly increases productivity of the facilities by avoiding emergency downtime, as well as optimizing mean time between maintenances. The results of analysis carried out at one of the larger company from the sector have shown, that one machine working at the plant is able to generate additional significant profit, if only it is possible to avoid any unplanned downtime and production of poor quality caused by worn out parts, that should have been replaced. It is at least 975 000 USD per year, that is 12.5% of annual maintenance budget. It is a tangible proof that the constant diagnostic supervision of production facilities is the source of additional profits for the customer.
The problems of maintenance have accompanied and ‘threatened’ the working people ever since the application of equipment. It was experienced from the beginning that equipment could go wrong and machines could break down. Humans have been and still are working on solutions to these problems, so it is not an exaggeration to say that maintenance is the same age as humanity and manufacturing activities.
Maintenance techniques have changed over time from correction (breakdown) to prevention to prediction and pro-active continuous improvement. Effective maintenance is a series of progressive steps to improve operational effectiveness and the key step in this process is the transition of pro-active working. Companies that optimise their maintenance select and combine the techniques that match the needs of their equipment and operations.
There is another important approach in this chain of thoughts. What breakdowns are typical for printing machines? The classification of breakdowns is carried out according to the 10 big structural groups characterising the printing machines:
- Input Unit
- Main Operational Unit
- Output Unit
- Mechanical driving force
- Electrical driving force
- Electrical controlling unit
- Beacons, sensors
- Energy Supply
- Air-technique service
The input and output units give the 39% of all breakdowns. There is a high occurrence of breakdowns due to failures of mechanical propulsion, sensors and beacons. Units performing technologically important operation have relatively smaller breakdown proportion compared to their importance in the machinery. The breakdown proportion of the electrical parts is 20%. The knowledge of proportions is especially interesting when preparing for condition-assessment and modernization.
For the productivity maintenance of printing machines the detailed knowledge of relations of failures are crucial. Reparation of unexpected breakdowns generally requires management of short/reactive reparation. Knowledge about the typical failure rates of major parts of printing machines is the fundamental pillar to apply pro-active maintenance management.
A periodic monitoring and measurement system will provide a simple and effective warning of impeding failure and the on-going cost savings are anticipated.
We can provide solutions for both online and offline monitoring, with all our monitoring systems being designed for use in the toughest environments, including hazardous areas.
The benefits for using a condition monitoring system:
- improve productivity
- improve energy efficiency
- minimize the risk of unplanned downtime
- high quality
- optimize design
- optimize manpower resources
- reduce time to market
- reduce maintenance cost
- reduce total cost of ownership
- extends the useful life of equipment