Quick criticality analysis can save both the equipment and the production

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If the maintenance of an industrial plant is not appropriate, there are often unmanageable problems in production. In order for maintenance to be systematic and efficient, the most critical points in the production process must be identified. When using traditional models, criticality analysis can take several months.

- We have developed a simulation process that allows us to carry out a criticality analysis of equipment in five days, and to update the preventive maintenance programs accordingly, says Development Manager Toni Räisänen, who belongs to the team developing productivity and digital services at Maintpartner.

In the quick update, the plant is simulated using the maintenance system’s hierarchical data and the historical data collected from the site CMMS, Computerized Maintenance Management System. Simulation finds out the most unreliable and unproductive items from a large number of findings.

- Quick upgrade is a visual presentation of changes in criticality. It also shows how previous maintenance programs have succeeded, and whether abnormalities occur that have not been observed before, says Toni Räisänen.

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Clear presentation of results

One of the analyzed customers is Lantmännen Unibake bakery in Joutseno, Finland. The simulation showed that of the over 2,000 devices in the entire plant only about 5 percent require upgrade – in this share is included the greatest savings potential with the fastest achievability.

- We visualize the results, and based on the chart colors we can immediately see where there is most red, that is, need for corrective measures. There is no need for accurate analysis of all devices, but focus on change, starting with the most critical thirty items, Räisänen describes.

Below you can see how Maintpartner presents the system-level criticalities in one picture. In the center is the Joutseno plant and the outer edges show the factory components and equipment.

Failure mode and effect analysis is performed for selected items and their preventive maintenance programs are refined.

Quick upgrades can be made for example every year to check that everything is as it should be, and that maintenance has done the right things. The same model is applicable all industries.


Picture: Visualization of system-level criticalities as presented by Maintpartner. The Joutseno plant in the middle and components and equipment in the outer edges.


Further information:
Toni Räisänen, Development Manager, Maintpartner, +358 50 441 2494, toni.raisanen [at] maintpartner.com

Otto Tarkiainen, President, Productivity and digital solutions, Maintpartner,
+358 40 176 3112, otto.tarkiainen [at] maintpartner.com