Preventive vs Reactive Maintenance: Umhlahlandlela Wabasebenzi Base-SA

Ukuphuka okungahlelekile kubiza imisebenzi yaseNingizimu Afrika izinkulungwane ekulahlekelweni ukukhiqiza, ukubiza ngokushesha nengozi yokungahambisani. Ukukhetha phakathi kwe-preventive vs reactive maintenance kuhlela ukungasebenzi kwakho, irekhodi lokuphepha nenzalo. Ukudonswa kwamandla, ukushoda kobuchwepheshe nemithetho eqinile yokuphepha kwenza lokho kukhetho kubaluleke kakhulu.

Lo mhlahlandlela uhlanganisa ukuthi isu ngasinye sisho ini, nini ngasinye sinengqondo, sibiza malini nendlela yokudlulela ekulweni nomlilo kuya ekulungiseni okuhleliwe — nezibonelo ezimayini, ezimbonini nasezindaweni esimeni sase-SA.

Iyini i-Reactive Maintenance?

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

Isebenza kanjani empraktishini

Akukho misebenzi ehleliwe: ukulungisa kwenziwa kuphela lapho okuthile kuyeke ukusebenza noma kuphuke ngokucacile.
Ukubiza okuphuthumayo: ochwepheshe baphendula ukuphuka, ngokuvamile ngaphandle kwezikhathi ezivamile.
Ukushintsha noma ukulungisa lapho: izinqumo zenziwa ngaphansi kwengcindezi, nenesikhathi esilinganiselwe sokuthola izingxenye ezifanele noma ukuhlela umsebenzi kahle.

Lapho i-reactive maintenance iyisisekelo

Imisebenzi eminingi idonsela ku-reactive maintenance ngenxa yengcindezi: izabelomali eziqinile, amaqembu angaphezu kwabasebenzi, noma isiko lapho “uma kungaphukile, ungayithinti.” Esikhathini esifushane kungazizwa kushibhile ngoba awusebenzisi ekusebenzeni okuhleliwe — kodwa indleko yesikhathi eside ngokuvamile iphezulu kakhulu.

Iyini i-Preventive Maintenance?

I-Preventive maintenance (PM) ngumsebenzi ohleliwe owenziwa ngaphambi kokuphuka ukuze ugcine impahla isesimweni esihle futhi unciphise ithuba lokuphuka okungahlelekile. Inzuzo ye-preventive maintenance ebaluleke kakhulu iyimpilo ende yezimpahla, ukuvimba okungahlelekile okuncane, imisebenzi ephephile, nenzalo ephansi yohlelo ngehora. I-PM ingaba ngesikhathi, nge-mitha, noma ngosimo.

I-Preventive maintenance ngesikhathi

Imisebenzi ihlelwa ngezikhathi eziqinile: iviki ngaviki, nyanga ngonyanga, nkanga ngenkanga, noma unyaka ngonyaka. Izibonelo:

Ukulungisa i-mine hoist: Ukugcoba nokuhlola amabhreyki nyanga ngonyanga, ukuhlolwa kwentambo nokuhlolwa komthwalo unyaka ngonyaka, njengoba kudingwa uMthetho Wezempilo Nokuphepha Ezimayini (MHSA).
I-HVAC ezakhiweni zamabhizinisi: Ukushintsha amafilter nkanga ngenkanga, ukuhlanza i-coil nokuhlola i-refrigerant unyaka ngonyaka.

I-PM ngesikhathi ilula ukumisa futhi isebenza kahle lapho ukuphuka kuxhumene kakhulu nobudala noma ukusebenzisa ikhalenda.

I-Preventive maintenance nge-mitha

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

Izinhlelo zebhande lesidlulisi: Shintsha ama-idler bearing njalo ngamahora angu-20,000 asebenzayo; hlola ama-belt splice njalo ngamahora angu-5,000.
Amasethi ojenaretha: Ukushintsha uwoyela nefilter njalo ngamahora angu-500 asebenzayo — ikakhulukazi eNingizimu Afrika lapho ukudonswa kwamandla kuvame.

I-PM nge-mitha ihlanganisa imisebenzi nokuguga kwangempela futhi inganciphisa ukungenelela okungadingeki empahleni esebenzisa kancane.

I-Preventive maintenance ngosimo

Umsebenzi uhlelwa lapho izinkomba zibonisa ukuthi isimo siyehla: ukudlidliza, ukushisa, ukuhlaziya uwoyela, noma ukuhlola ngamehlo. Izibonelo:

Amapompu abalulekile: Shintsha ama-bearing lapho ukudlidliza kudlula umkhawulo.
I-electrical switchgear: Ukuhlolwa kwe-thermographic ukuze ubambe ama-hot spot ngaphambi kokuphuka.

I-PM ngosimo inganciphisa indleko futhi ithuthukise ukuthembeka lapho unedatha efanele nobuchwepheshe bokwenza ngayo.

Ukuqhathanisa Izindleko: Kungani i-Reactive Ivame Ukubiza Kakhulu

Ucwaningo namabhentshimaki wombusi bakhombisa ngokungaguquki ukuthi ukulungisa okulandela kubiza kakhulu ukulungisa ngakho konke ukulungisa okuhleliwe. Umqondo we-80/20 uyasiza: ingxenye enkulu yezindleko zakho zokulungisa ivame ukuvela engxenyeni encane yokuphuka okungavike noma kube sekuhle nge-preventive maintenance.

Kungani i-reactive maintenance ibiza kakhulu

Ukungasebenzi okungahlelekile — Ukukhiqiza kuyema lapho ungakulindeli. Ezimayini nasebhasini, ihora elilodwa lokulahlekelwa ukukhiqiza lingadlula amanyanga omsebenzi we-PM.
Abasebenzi abaphuthumayo — Ukubiza, ukusebenza isikhathi esengeziwe, nomsebenzi wekephethelwa kubiza kakhulu kukushifti ehleliwe.
Umonakalo owesibili — I-bearing ephukile ingonakalisa i-shaft noma imoto; uphawu okuvuzayo lungonakalisa ama-electronics. Ukulungisa okulandela kuvame ukuhlanganisa umonakalo ophathelene.
Ukukhetha izingxenye okungesihle — Ngaphansi kwengcindezi ungasebenzise noma yini etholakalayo esikhundleni sengxenye efanele, okuholela ekuphukeni okuphindaphindayo.
Ingozi yokuphepha nokuhambisana — Ukuphuka okungazelelwe kungadala okusondele noma ukulimala; run-to-failure nayo kwenza kube nzima ukufakazela ukulungisa okuhleliwe ukuhambisana ne-OHS Act ne-MHSA.

Umthetho ojwayelekile wokuthi i-reactive maintenance ingabiza izikhathi ezintathu kuya eziyisishiyagalombili kune-preventive maintenance empilweni yempahla. Inani eliqondile lixhomeke ekutheni impahla ibaluleke kangakanani nangenani yokungasebenzi okungahlelekile kubiza umsebenzi wakho.

Isibonelo: i-PM yebhande lesidlulisi vs ukulungisa okulandela

Umsebenzi wegolide noma i-platinum ugijimisa isidlulisi esibalulekile kusukela e-stope kuya phezulu. Ngaphandle kwe-PM:

I-idler ephukile ionakalisa ibhande; ukukhiqiza kuyema amahora ayi-12.
Inzalo: R80,000 ukulahlekelwa ukukhiqiza + R25,000 ukulungisa okuphuthumayo + R15,000 umonakalo webhande = R120,000.

Ngesheduli yokuhlola ne-idler eshintshiwe njalo ngamahora angu-20,000:

Ukuvala okuhleliwe: amahora amabili, i-idler eshintshiwe phambili. Inzalo: cishe R8,000 abasebenzi nezingxenye + umthelela omncane kokukhiqiza uma kuhlelwe ewindini lokulungisa.

Indlela ye-preventive kulesi sibonelo iyingxenye yenzalo ye-reactive futhi igwema ingozi yokuphepha yokuphuka kwebhande okungazelelwe.

Lapho i-reactive maintenance yamukelekile

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

Impahla ayibalulekile — Ukuphuka akuthinti ukuphepha, ukukhiqiza, noma ukuhambisana. Isibonelo: ipompu ezingasekho esetshenziswa kuphela lapho ipompu eyinhloko iphansi.
Kukhona ukuphindaphinda — Amayunithi amaningi enza umsebenzi ofanayo; uma owodwa uphuka, amanye athwala umthwalo ngenkathi ulungisa.
Impahla ishibhile noma iyalahlekwa — Ukushintsha ifeni encane noma imoto eshibhile kushibhe kukuhlela i-PM.
Ukuphuka kunzima ukuqagela — Ekuphukeni okuthile kungahle kube okungahlelekile (isib. ukushaywa yaduma, ukona); i-PM ingase inganciphisi kakhulu.

Kokunye konke — ikakhulukazi impahla ebalulekile ukuphepha nokukhiqiza — isu lokulungisa okuhleliwe kuyinketho engcono yesisekelo. Bhala phansi ukuthi yiziphi izimpahla ozimisele ugcine ngesu le-reactive bese uhlola lelo luhlu ngezikhathi ezithile. Njengoba imisebenzi ikhula noma imithetho iqina, ezinye zaleyo zimpahla zingadinga ukudlulela ohlelweni oluhleliwe.

Isimo SaseNingizimu Afrika

Izinto ezintathu zenza isinqumo se-preventive vs reactive maintenance sibaluleke ikakhulukazi e-Ningizimu Afrika.

Ukudonswa kwamandla nokuphuka okulandela

Ukuvala amandla okuvamile kubanga ama-voltage dip, ukuqala okuqinile, nokushisa okushisayo. Ama-generator namasistimu we-UPS asebenza kakhulu futhi ngaphansi kwezimo ezinzima. Impahla okungenzeka yahlala iminyaka emandleni azinzikayo ingaphuka phambili. Ngaphandle kohlelo lwe-planned maintenance lwamandla okusekela nempahla yikagesi ebalulekile, uqeda ngokulandela: ukuphuka okunye, ukubiza okunye okuphuthumayo. I-Preventive maintenance kuma-generator, amaswishi okudlulisa, nempahla yikagesi ebalulekile ayiseyona inketho; iyingxenye yokuhlala usebenza ngesikhathi sokudonswa kwamandla.

Ukushoda kobuchwepheshe nokuqedwa kwe-PM

Ukushoda kobuchwepheshe baseNingizimu Afrika kuthinta ukuqedwa kokulungisa. Ama-artisan namainjiniya amancane asho:

Amandla amancane okwenza umsebenzi ohleliwe, ngakho i-backlog ikhula futhi i-PM ihlehliswa.
Ukuthembela okuningi ekulungiseni okulandela ngoba “sinesikhathi sokuthi ukuphuka kuphela.”

Impendulo akuyona ukushiya i-PM kodwa ukubeka okuqala: gxila i-preventive maintenance ezimpahleni ezibaluleke kakhulu, senciphise izinqubo, futhi usebenzise i-CMMS ukuhlela nokulandelela ukuze isikhathi sabasebenzi esilinganiselwe sisetshenziswe emisebenzini efanele.

I-OHS Act nokulungisa okuhleliwe

UMthetho Wezempilo Nokuphepha Emsebenzini (Act 85 ka-1993) nemithetho ehlobene idinga abaqashi ukuthi balungise isitshalo nempahla ngosimo oluphephile. Ezimayini, i-MHSA nemithetho ehlobene ibeka izimfuneko ezicacile zokuhlolwa okuhleliwe nokulungisa izinhlelo zokudonsa, izidlulisi nempahla enye. Ukuthembela kuphela ku-reactive maintenance kwenza kube nzima ukukhombisa indlela ehlelekile yokuphepha. Ukulungisa okuhleliwe — okubhalwe phansi nokuqediwe — kusekela ukuhambisana futhi kunciphisa ingozi yomthetho nedumela.

Indlela Yokudlulela Kusuka Ku-Reactive Kuya Ku-Preventive Maintenance

Ukudlulela ku-reactive kuya ku-preventive akudingi iphrojekthi enkulu. Indlela enezingxenye isebenza kahle.

1. Ukuhlaziya ukubaluleka kwezimpahla

Bhala phansi izimpahla zakho eziyinhloko bese uziklela nge:

Umthelela wokuphuka kokuphepha, ukukhiqiza, imvelo, nokuhambisana.
Inzalo yokungasebenzi okungahlelekile.
Ubuningi bokusebenzisa nokuchayeka ezimweni ezinzima (isib. ukudonswa kwamandla).

Gxila umzamo wakho wokuqala we-preventive maintenance ezimpahleni ezingaphezu kwe-20% eziphakamisa ingozi nenzalo eningi.

2. Qala ngempahla enenani eliphezulu

Beka okuqala impahla lapho ukuphuka okungahlelekile kubulala kakhulu: izidlulisi zemayini, izidlulisi eziyinhloko, ama-generator, amapompu abalulekile, isitshalo se-HVAC ezakhiweni ezigcwele. Ngayinye, chaza:

Okufanele kwenziwe (ukugcoba, ukuhlola, ukushintsha izingxenye ezigugayo).
Kangaki (ngesikhathi noma nge-mitha), usebenzisa umhlahlandlela we-OEM nomlando wakho.
Ngubani oyenza nokuthi kufanele kuthathe isikhathi singakanani.

Hlola uhlelo lwakho lwe-PM ezimpahleni ezimbalwa ebalulekile, bese unweba uma inqubo isezimile.

3. Sebenzisa i-FMECA (noma okuhlukile okulula) lapho kusiza

I-Failure Modes, Effects and Criticality Analysis (FMECA) iyindlela ehlelekile yokubhala phansi izindlela zokuphuka, imithelela yazo, nendlela yokuvimbela noma ukuthola. Awudingi i-FMECA ephelele yempahla ngayinye. Impahleni ebalulekile, ngisho ithebula elilula liyasiza:

Indlela yokuphuka (isib. ukubanjwa kwe-bearing).
Umthelela (isib. ukuvimba isidlulisi, umonakalo webhande).
Ukuvimbela (isib. ukugcoba nokulandelela isimo).
Ukuthola (isib. ukuhlola ukudlidliza noma ukushisa).

Lelo thebula lisebenza ngqo emisebenzini yakho ye-preventive maintenance nasezikhathini.

4. Hlela futhi ulandelele ku-CMMS

Isistimu yokulawula ukulungisa ekhompyuteriwe (CMMS) iguqula icebo lakho libe umsebenzi ohleliwe: imisebenzi ephindaphindayo, ama-work order, amakhophi nomlando. Ngaphandle kwayo, i-PM ivame ukushiyeka lapho abantu basebenza nokuphuka. Ngayo, ungangabona okufanele, okwenziwe nokudlulelwe — futhi ugcine ukudlulela ku-reactive kuya ku-preventive kusemgqeni.

Ama-KPI okulandelela

Lapho une-preventive maintenance, landelela amamethrikhi ambalwa abalulekile.

Ukuhambisana kwe-PM (iphesenti lokuqeda i-PM)

Iphesenti lemisebenzi ye-PM ehleliwe eqediwe ngesikhathi. Iphuzu: ngokuvamile 90% noma ngaphezulu ezimpahleni ebalulekile. Ukuhambisana okuphansi kusho ukuthi icebo aliqediwa futhi usalokhu ulandela ngempela.

I-MTBF (Mean Time Between Failures)

Isikhathi esiphakathi sokusebenza phakathi kokuphuka kwempahla noma uhlobo lwempahla. Njengoba i-preventive maintenance isebenza, i-MTBF kufanele ithuthuke. Yisebenzise ukuqhathanisa ngaphambi nangemva kokungenisa i-PM. Ukuthola ukuhlaziya okujulile, bheka umhlahlandlela we-MTBF ne-MTTR wemisebenzi yaseNingizimu Afrika.

I-MTTR (Mean Time To Repair)

Isikhathi esiphakathi esukela ekuphukeni kuya ekulungiseni. I-MTTR ibonisa ukukwazi kwakho ukuxilonga, ukuthola izingxenye, nokulungisa. Ayithathi indawo ye-PM kodwa ikhombisa ukuthi uphatha kanjani ukuphuka okuqhubekayo.

Isilinganiso sokuhleliwe vs okungahlelekile

Iphesenti lamahora okulungisa (noma ama-work order) ahleliwe vs angahlelekile. Iphuzu elivamile ngu-80% ehleliwe, 20% angahlelekile. Ukudlulela kusuka ku-30% ehleliwe kuya ku-70% ehleliwe kuyisiboniso esicacile sokuthi usuka kokulandela kuya ku-preventive.

Indima Ye-CMMS Ekwenzeni I-Preventive Maintenance

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

Ama-work order aphindaphindayo — Imisebenzi ikhiqizwa ngokuzenzakalelayo ngesikhathi noma nge-mitha ukuze lutho lukhohlwe.
Amakhophi nezindinganiso — Umsebenzi we-PM ngamunye unenqubo ecacile, ethuthukisa ukuvumelana nokudlulisa.
Ukubonakala — Amadashibhodi nemibiko akhombisa ukuhambisana kwe-PM, i-backlog, nomsebenzi odlulelwe ukuze ukwazi ukubeka okuqala.
Umlando — Irekhodi ephelele yokwenziwe, nini, nangobani — kubalulekile ekuhloleni nasekucubunguleni izikhathi.
Izingxenye nabasebenzi — Xhumanisa imisebenzi nezingxenze nabasebenzi ukuze ukwazi ukuhlela izinsiza futhi ubone inzalo yangempela ye-PM vs reactive.

Imisebenzi yaseNingizimu Afrika ephathelene nokudonswa kwamandla, izingcindezi zobuchwepheshe, nemithetho yokuphepha, i-CMMS iyithululi elisebenzayo esenza isu lokulungisa iNingizimu Afrika ithembeke — hhayi nje ephepheni, kodwa ekwenzeni nsuku zonke. Iphinde idale inye yokuhlola abahloli namashu abalindelayo lapho bebuzisa ukuthi ulungisa kanjani impahla ebalulekile neyokuphepha.

Isiphetho

Ukukhetha phakathi kwe-preventive vs reactive maintenance akuyona yonke-noma-lutho: sebenzisa i-reactive lapho iamukelekile (izimpahla ezingabalulekile, eziphindaphindiwe noma ezishibhile) bese usebenzisa i-preventive lapho ukuphuka kubiza noma akuphophe. E-Ningizimu Afrika, ukudonswa kwamandla, ukushoda kobuchwepheshe ne-OHS Act (ne-MHSA ezimayini) kwenza ukulungisa okuhleliwe kubaluleke kakhulu. Qala ngezimpahla ebalulekile, chaza imisebenzi nezikhathi ezicacile, futhi usebenzise i-CMMS ukuhlela nokulandelela ukuze iqembu lakho likwazi ukuqeda ngokungaguquki.

Bona ukuthi i-Lungisa isiza kanjani imisebenzi yaseNingizimu Afrika ukusuka kokulungisa okulandela kuya ema-work order ahleliwe, ahlolwayo — ngokuhlela kwe-preventive maintenance, ama-work order aphindaphindayo nokulandelela ukuhambisana ne-OHS Act ne-MHSA okusebenza ngaphandle kwe-inthanethi ngesikhathi sokudonswa kwamandla.