I-Preventive vs Reactive Maintenance: Umhlahlandlela Wemisebenzi yase-SA

Ukuphuka okungahlelekile kubiza imisebenzi yaseNingizimu Afrika izinkulungwane ekulahlekelweni ukukhiqiza, ukubizwa kwezimo eziphuthumayo kanye nengozi yokungahambisani nemithetho. Ukukhetha phakathi kwe-preventive vs reactive maintenance kubumba ukungasebenzi kwakho, irekhodi lokuphepha nenzuzo. Ukudonswa kukagesi (load-shedding), ukushoda kobuchwepheshe nemithetho eqinile yokuphepha kwenza lokho kukhetha kubaluleke nakakhulu, hhayi kancane.

Lo mhlahlandlela uhlanganisa ukuthi isu ngasinye lisho ini, nini isu ngasinye lisebenza, sibiza malini nendlela yokudlulela ekulweni nomlilo (firefighting) kuya ekulungisweni okuhleliwe, nezibonelo ezivela emayini, ezimbonini nasezindaweni zomsebenzi esimeni sase-SA.

Iyini i-Reactive Maintenance?

I-Reactive maintenance (evame ukubizwa ngokuthi run-to-failure) kusho ukuthi ulungisa impahla kuphela ngemva kokuba iphuke. Akukho ukuhlola noma ukusebenza okuhleliwe; umsebenzi uqaliswa ukuphuka, ukungasebenzi, noma isikhalazo.

Isebenza kanjani empraktikweni

Akukho misebenzi ehleliwe: ukulungisa kwenziwa kuphela lapho okuthile kuyeka ukusebenza noma kuphuke ngokusobala.
Ukubizwa okuphuthumayo: ochwepheshe baphendula ukuphuka, ngokuvamile ngaphandle kwamahora ajwayelekile.
Ukushintsha noma ukulungisa khona lapho: izinqumo zithathwa ngaphansi kwengcindezi, ngesikhathi esilinganiselwe sokuthola izingxenye ezifanele noma ukuhlela umsebenzi kahle.

Lapho i-reactive maintenance iyisisekelo esejwayelekile

Imisebenzi eminingi iwela ku-reactive maintenance ngenxa yengcindezi: izabelomali eziqinile, amaqembu angenabo abasebenzi abenele, noma isiko lapho “uma kungaphukile, ungakuthinti.” Esikhathini esifushane kungazwakala kushibhile ngoba awukhokhi ukusebenza okuhleliwe, kodwa indleko yesikhathi eside ivame ukuba phezulu kakhulu.

Iyini i-Preventive Maintenance?

I-Preventive maintenance (PM) ngumsebenzi ohleliwe owenziwa ngaphambi kokuphuka ukuze ugcine impahla isesimweni esihle futhi unciphise amathuba okuphuka okungahlelekile. Izinzuzo ze-preventive maintenance ezibaluleke kakhulu yimpilo ende yezimpahla, ukuma okuphuthumayo okuncane, imisebenzi ephephe ngokwengeziwe, kanye nendleko ephansi jikelele ngehora lokusebenza. I-PM ingaba ngesikhathi, nge-mitha, noma ngesimo.

I-Preventive maintenance esekelwe esikhathini

Imisebenzi ihlelwa ngamaviyalintaba aqinile: masonto onke, nyanga zonke, nkathi zonke, noma minyaka yonke. Izibonelo:

Ukulungiswa kwe-mine hoist: Ukugcotshwa nokuhlolwa kwamabhuleki nyanga zonke, ukuhlolwa kwentambo nokuhlolwa komthwalo minyaka yonke, njengoba kudingwa uMthetho Wezempilo Nezokuphepha Ezimayini (MHSA).
I-HVAC ezakhiweni zamabhizinisi: Ukushintshwa kwamafilter nkathi zonke, ukuhlanzwa kwe-coil nokuhlolwa kwe-refrigerant minyaka yonke.

I-PM esekelwe esikhathini ilula ukuyihlela futhi isebenza kahle lapho ukuphuka kuxhumene kakhulu nobudala noma ukusetshenziswa ngekhalenda.

I-Preventive maintenance esekelwe kumitha

Umsebenzi uqaliswa ukusetshenziswa (amahora asebenzayo, amakhilomitha, imijikelezo, amathani akhiqiziwe). Izibonelo:

Izinhlelo zebhande lokuhambisa impahla: Shintsha ama-idler bearing njalo emva kwamahora angu-20 000 asebenzayo; hlola ama-belt splice njalo emva kwamahora angu-5 000.
Amasethi ka-generator: Ukushintsha uwoyela nefilter njalo emva kwamahora angu-500 asebenzayo, ikakhulukazi lapho ukudonswa kukagesi kuvame khona eNingizimu Afrika.

I-PM esekelwe kumitha ihambisana nemisebenzi nokuguga kwangempela futhi inganciphisa ukungenelela okungadingekile empahleni esetshenziswa kancane.

I-Preventive maintenance esekelwe esimweni

Umsebenzi uhlelwa lapho izinkomba zibonisa ukuthi isimo siyehla: ukuzamazama, ukushisa, ukuhlaziywa kukawoyela, noma ukuhlolwa ngeso. Izibonelo:

Amapompu abalulekile: Shintsha ama-bearing lapho ukuzamazama kudlula umkhawulo.
I-electrical switchgear: Ukuhlolwa kwe-thermographic ukuze kubanjwe izindawo ezishisayo ngaphambi kokuphuka.

I-PM esekelwe esimweni ingehlisa izindleko futhi ithuthukise ukwethembeka lapho unedatha efanele nobuchwepheshe bokusebenza ngayo.

Ukuqhathanisa Izindleko: Kungani i-Reactive Ivame Ukubiza Kakhulu

Ucwaningo namabhentshimaki ombuso wembali abonisa ngokuqhubekayo ukuthi i-reactive maintenance ibiza kakhulu ngokuncintisana nomsebenzi ohleliwe, ngokobhaka olulodwa lokulungiswa. Umqondo we-80/20 uyasiza: ingxenye enkulu yezindleko zakho zokulungisa ivame ukuvela engxenyeni encane yokuphuka okwakungagwenywa noma kwaliswa nge-preventive maintenance.

Kungani i-reactive maintenance ibiza kakhulu

Ukungasebenzi okungahlelekile: Ukukhiqiza kuyema lapho ungakulindele. Emayini noma embonini, ihora elilodwa lokulahlekelwa ukukhiqiza lingadlula izinyanga zomsebenzi we-PM.
Abasebenzi abaphuthumayo: Ukubizwa okuphuthumayo, ukusebenza isikhathi esengeziwe, nomsebenzi wangempelasonto kubiza kakhulu kunamashiphu ahleliwe.
Umonakalo wesibili: I-bearing eyonakele ingonakalisa i-shaft noma imoto; iseal evuzayo ingonakalisa ama-electronics. Ukulungiswa ngendlela ye-reactive kuvame ukuhlanganisa umonakalo owengeziwe.
Ukukhetha izingxenye okungesihle: Ngaphansi kwengcindezi ungasebenzisa noma yini etholakalayo esikhundleni sengxenye efanele, okuholela ekuphukeni okuphindaphindayo.
Ingozi yokuphepha nokuhambisana nemithetho: Ukuphuka okuzumayo kungabangela izigameko ezingaphephile noma ukulimala; i-run-to-failure ikwenza futhi kube nzima ukufakazela ukulungisa okuhleliwe ukuze kuhambisane ne-OHS Act ne-MHSA.

Umthetho ojwayelekile uthi i-reactive maintenance ingabiza izikhathi ezintathu kuya eziyisishiyagalombili ngaphezulu kune-preventive maintenance ekuphileni konke kwempahla. Isibalo esiqondile sixhomeke ekutheni impahla ibaluleke kangakanani nokuthi ukungasebenzi okungahlelekile kubiza malini emsebenzini wakho.

Isibonelo: i-PM yebhande lokuhambisa impahla vs ukulungisa nge-reactive

Umsebenzi wegolide noma iplatinamu usebenzisa ibhande elibalulekile elisuka e-stope kuya phezulu. Ngaphandle kwe-PM:

I-idler encibilikile yonakalisa ibhande; ukukhiqiza kuyema amahora angu-12.
Indleko: R80 000 ukulahlekelwa ukukhiqiza + R25 000 ukulungisa okuphuthumayo + R15 000 umonakalo webhande = R120 000.

Ngesheduli yokuhlola ne-idler eshintshwayo njalo emva kwamahora angu-20 000:

Ukuvala okuhleliwe: amahora amabili, i-idler ishintshwe ngaphambili. Indleko: cishe R8 000 abasebenzi nezingxenye + umthelela omncane ekukhiqizeni uma kuhleliwe ewindini lokulungisa.

Indlela ye-preventive kulesi sibonelo iyingxenye encane yendleko ye-reactive futhi igwema ingozi yokuphepha yokuphuka kwebhande okuzumayo.

Lapho i-reactive maintenance yamukelekile

I-Preventive maintenance akusiyo njalo inketho efanele. I-Reactive maintenance ingamukeleka lapho:

Impahla ingabalulekile: Ukuphuka akuthinti ukuphepha, ukukhiqiza, noma ukuhambisana nemithetho. Isibonelo: ipompu yesigcino esetshenziswa kuphela lapho ipompu enkulu ingasebenzi.
Kukhona ukuphindaphinda: Amayunithi amaningi enza umsebenzi ofanayo; uma elilodwa liphuka, amanye athwala umthwalo ngenkathi ulilungisa.
Impahla ishibhile noma iyalahlwa: Ukushintsha ifeni encane noma imoto eshibhile kushibhe kunokuhlela i-PM.
Ukuphuka kunzima ukukuqagela: Okunye ukuphuka kungahlelekile (isib. ukushaywa yindudumela, ukona); i-PM ingase inganciphisi kakhulu.

Kokunye konke, ikakhulukazi impahla ebalulekile ekuphepheni nasekukhiqizeni, isu lokulungisa okuhleliwe lihamba phambili njengesisekelo esingcono. Bhala phansi ukuthi yiziphi izimpahla ozihlela ngamabomu ukuba zihlale ku-reactive strategy bese uhlola lolo hlu njalo. Njengoba imisebenzi ikhula noma imithetho iqina, ezinye zaleyo zimpahla zingase zidinge ukudlulela ohlelweni oluhleliwe.

Isimo SaseNingizimu Afrika

Izici ezintathu zenza isinqumo se-preventive vs reactive maintenance sibaluleke ikakhulukazi eNingizimu Afrika.

Ukudonswa kukagesi nokuphuka nge-reactive

Ukuvalwa kukagesi okuvamile kubangela ama-voltage dip, ukuqala okunzima, nokushisa okuphindaphindayo. Ama-generator namasistimu we-UPS asebenza kaningi futhi ngaphansi kwezimo ezinzima. Impahla ebingase ihlale iminyaka emandleni azinzile ingaphuka ngokushesha. Ngaphandle kohlelo lokulungisa okuhleliwe lwamandla asekelayo nempahla ebucayi, uphelela emzileni we-reactive: ukuphuka okunye, ukubizwa okunye okuphuthumayo. I-Preventive maintenance kuma-generator, ama-transfer switch, nempahla ebalulekile kagesi akusenakuba inketho; kuyingxenye yokuhlala usebenza phakathi nokudonswa kukagesi.

Ukushoda kobuchwepheshe nokuqedwa kwe-PM

Ukushoda kobuchwepheshe baseNingizimu Afrika kuthinta ukuqedwa komsebenzi wokulungisa. Ama-artisan namainjiniya abancane basho ukuthi:

Kunamandla amancane okwenza umsebenzi ohleliwe, ngakho ama-backlog akhula futhi i-PM ihlehliswa.
Kuncike kakhulu ekulungiseni nge-reactive ngoba “sinesikhathi sokubhekana nokuphuka kuphela.”

Impendulo akusikho ukuyeka i-PM kodwa ukubeka izinto ezibalulekile kuqala: gxila i-preventive maintenance ezimpahleni ezibaluleke kakhulu, wenze izinqubo zibe lula, futhi usebenzise i-CMMS ukuhlela nokulandelela ukuze isikhathi sabasebenzi esilinganiselwe sisetshenziswe emisebenzini efanele.

I-OHS Act nokulungisa okuhleliwe

UMthetho Wezempilo Nezokuphepha Emsebenzini (Act 85 ka-1993) nemithetho ehlobene nawo idinga ukuthi abaqashi bagcine izitshalo nempahla zisesimweni esiphephile. Emayini, i-MHSA nemithetho ehlobene nayo ibeka izimfuneko ezicacile zokuhlolwa nokulungiswa okuhleliwe kwezinhlelo zokudonsa (winding systems), amabhande okuhambisa impahla nempahla enye. Ukuncika kuphela ku-reactive maintenance kwenza kube nzima ukukhombisa indlela ehlelekile yokubhekana nokuphepha. Ukulungisa okuhleliwe, okubhalwe phansi futhi okwenziwa ngempela, kusekela ukuhambisana nemithetho futhi kunciphisa ingozi yomthetho nedumela.

Indlela Yokudlulela Kusuka Ku-Reactive Kuya Ku-Preventive Maintenance

Ukudlulela kusuka ku-reactive kuya ku-preventive akudingi iphrojekthi enkulu enye. Indlela enezigaba isebenza kahle.

1. Ukuhlaziya ukubaluleka kwezimpahla

Bhala uhlu lwezimpahla zakho eziyinhloko bese uzihlela ngokuthi:

Umthelela wokuphuka ekuphepheni, ekukhiqizeni, emvelweni, nasekuhambisaneni nemithetho.
Indleko yokungasebenzi okungahlelekile.
Ukuvama kokusetshenziswa nokuchayeka ezimweni ezinzima (isib. ukudonswa kukagesi).

Gxila imizamo yakho yokuqala ye-preventive maintenance kuma-20% aphezulu ezimpahla aholela ingozi nendleko eningi.

2. Qala ngempahla enenani eliphezulu

Beka phambili impahla lapho ukuphuka okungahlelekile kulimaza kakhulu: ama-mine hoist, amabhande amakhulu okuhambisa impahla, ama-generator, amapompu abalulekile, izitshalo ze-HVAC ezakhiweni ezigcwele. Kwenye ngayinye, chaza:

Okumele kwenziwe (ukugcoba, ukuhlola, ukushintsha izingxenye ezigugayo).
Kangaki (ngesikhathi noma nge-mitha), usebenzisa umhlahlandlela we-OEM kanye nomlando wakho.
Ubani owenzayo nokuthi kufanele kuthathe isikhathi esingakanani.

Qala uhlelo lwakho lwe-PM izimpahla ezimbalwa ezibalulekile njengesivivinyo, bese unweba uma inqubo isizinzile.

3. Sebenzisa i-FMECA (noma indlela elula) lapho kusiza

I-Failure Modes, Effects and Criticality Analysis (FMECA) yindlela ehleliwe yokubhala izindlela zokuphuka, imithelela yazo, nendlela yokukuvimbela noma ukukubona. Awudingi i-FMECA egcwele kuyo yonke impahla. Kwimpahla ebalulekile, ngisho ithebula elilula liyasiza:

Indlela yokuphuka (isib. i-bearing encibilika).
Umthelela (isib. ukuma kwebhande, umonakalo webhande).
Ukuvimbela (isib. ukugcotshwa nokuqapha isimo).
Ukuthola (isib. ukuhlolwa kokuzamazama noma ukushisa).

Leyo thebula ihlanganisela ngqo emisebenzini yakho ye-preventive maintenance kanye nasezikhathini zayo.

4. Hlela futhi ulandelele nge-CMMS

I-sistimu yokuphathwa kokulungisa ekhonjwe ikhompyutha (CMMS) iphendula uhlelo lwakho lube umsebenzi ohleliwe: imisebenzi ephindaphindayo, ama-work order, izinhlu zokuhlola nomlando. Ngaphandle kwayo, i-PM ivame ukushiyeka lapho abantu bematasa nokuphuka. Uma inayo, ungakwazi ukubona okusadingekile, okwenziwe nokusele emuva, futhi ugcine ukudlulela kusuka ku-reactive kuya ku-preventive kuhlala kusemgqeni.

Ama-KPI okuwalandelela

Uma usunayo i-preventive maintenance, landelela izilinganiso ezimbalwa ezibalulekile.

Ukuhambisana kwe-PM (iphesenti lokuqedwa kwe-PM)

Iphesenti lemisebenzi ye-PM ehleliwe eqedwe ngesikhathi. Umgomo: ngokuvamile ngu-90% noma ngaphezulu kwimpahla ebalulekile. Ukuhambisana okuphansi kusho ukuthi uhlelo lwakho aluqedwa futhi usenokuba ngoku-reactive ngempela.

I-MTBF (Isikhathi Esiphakathi Kokuphuka)

Isikhathi esiphakathi somsebenzi phakathi kokuphuka kwempahla noma uhlobo lwempahla. Njengoba i-preventive maintenance isisebenza, i-MTBF kufanele ithuthuke. Yisebenzise ukuqhathanisa ngaphambi nangemuva kokuqaliswa kwe-PM. Ukuze uthole ukuhlaziywa okujulile, bheka umhlahlandlela wethu we-MTBF ne-MTTR wemisebenzi yaseNingizimu Afrika.

I-MTTR (Isikhathi Esiphakathi Kuya Ekulungiseni)

Isikhathi esiphakathi esisuka ekuphukeni kuya ekulungiseni. I-MTTR ibonisa ikhono lakho lokuxilonga, ukuthola izingxenye, nokulungisa. Ayithathi indawo ye-PM kodwa ibonisa indlela ophatha ngayo ukuphuka okusaqhubeka.

Isilinganiso sokuhleliwe vs okungahlelekile

Iphesenti lamahora okulungisa (noma ama-work order) ahleliwe kune-angahlelekile. Umgomo ojwayelekile ngu-80% ohleliwe, 20% ongahlelekile. Ukudlulela kusuka ku-30% ehleliwe kuya ku-70% ehleliwe kuwuphawu olucacile lokuthi usuka ku-reactive uya ku-preventive.

Indima Ye-CMMS Ekwenzeni Kube Nokuhleleka Kwe-Preventive Maintenance

I-Preventive maintenance kunzima ukuyigcina ngamaklipbhodi namaspredishithi. I-CMMS ikunika:

Ama-work order aphindaphindayo: Imisebenzi ikhiqizwa ngokuzenzakalela ngokwesikhathi noma umitha ukuze lutho lungakhohlwa.
Izinhlu zokuhlola nezindinganiso: Umsebenzi ngamunye we-PM unenqubo ecacile, ethuthukisa ukufana nokudluliselwa komsebenzi.
Ukubonakala: Amadeshibhodi nemibiko abonisa ukuhambisana kwe-PM, ama-backlog, nomsebenzi osele emuva ukuze ukwazi ukubeka izinto ezibalulekile kuqala.
Umlando: Irekhodi eliphelele lokuthi kwenziweni, nini, futhi ngobani, okubalulekile ekuhlolweni nasekucwiliseleni izikhathi.
Izingxenye nabasebenzi: Xhuma imisebenzi ezingxenyeni nasebasebenzini ukuze ukwazi ukuhlela izinsiza futhi ubone indleko yangempela ye-PM uma iqhathaniswa ne-reactive.

Kwimisebenzi yaseNingizimu Afrika ebhekene nokudonswa kukagesi, izingcindezi zobuchwepheshe, nemithetho yokuphepha, i-CMMS yithuluzi elisebenzayo elenza isu lokulungisa iNingizimu Afrika engathembela kulo, hhayi nje ephepheni, kodwa emsebenzini wansuku zonke. Idale futhi umzila wokuhlola abahloli nabaqinisekisi abawulindele lapho bebuza ukuthi ulungisa kanjani impahla ebalulekile nehlobene nokuphepha.

Isiphetho

Ukukhetha phakathi kwe-preventive vs reactive maintenance akuyona into eyi-yonke-noma-lutho: sebenzisa i-reactive lapho yamukelekile (izimpahla ezingabalulekile, eziphindaphindiwe noma ezishibhile) bese usebenzisa i-preventive lapho ukuphuka kubiza kakhulu noma kungaphephile. ENingizimu Afrika, ukudonswa kukagesi, ukushoda kobuchwepheshe kanye ne-OHS Act (ne-MHSA emayini) kwenza ukulungisa okuhleliwe kubaluleke nakakhulu, hhayi kancane. Qala ngezimpahla ezibalulekile, chaza imisebenzi nezikhathi ezicacile, futhi usebenzise i-CMMS ukuhlela nokulandelela ukuze ithimba lakho likwazi ukwenza umsebenzi ngokuqhubekayo.

Bheka ukuthi i-Lungisa isiza kanjani imisebenzi yaseNingizimu Afrika ukusuka ekulungiseni nge-reactive kuya kuma-work order ahleliwe, angahlolwa, ngokuhlelwa kwe-preventive maintenance, ama-work order aphindaphindayo kanye nokulandelela ukuhambisana ne-OHS Act ne-MHSA okusebenza ngaphandle kwe-inthanethi phakathi nokudonswa kukagesi.