Eroon kalliista tuotantokatkoksista – miten teollisuuden tuotantotehokkuutta voisi lisätä?


Ennakoiva kunnossapito

Heittäisitkö sinä menemään 50 000 euroa? Et tietenkään. Ja harvoin kukaan niin tekisikään, mutta saman verran voi hyvinkin maksaa yhden tunnin tuotantokatkos prosessiteollisuudessa. Jos prosessin käynnistäminen kestää kaksi vuorokautta ja pysäyttäminen yhden vuorokauden, on selvää, että lyhyillekin ylimääräisille tuotantokatkoksille alkaa kertyä hintaa. Kysymys kuuluukin, voisiko teollisuuden kunnossapitoa tehostaa ja tuotantokatkoksia välttää nykyistä tehokkaammin?

Kokonaisvaltainen katkosten ennakointi avainasemassa

Kalliita tuotantokatkoksia esiintyy kaikilla prosessiteollisuuden aloilla sellu- ja kartonkitehtaista elintarviketeollisuuteen. Tarpeena on parantaa kokonaisvaltaisesti sekä prosesseja että tuotantolinjojen tehokkuutta, mutta tarjolla on lähinnä ratkaisuja osaongelmiin.

Asiaa voi havainnollistaa teollisuuden kunnossapidon näkökulmasta. Yhden tehtaan laitekanta on valtava ja siihen saattaa kuulua jopa 150 000 laitetta. Jos tuotannon kannalta kriittisiä laitepisteitä on esimerkiksi viisi- tai kymmenentuhatta, saattaa niistä vain esimerkiksi 400 olla reaaliaikaisen valvonnan piirissä, sillä kokonaisvaltainen seuranta tulisi aivan liian hintavaksi. Siksi on aina olemassa riski, ettei muutaman viikon välein tapahtuva mittauskierto osu tiettyjen laitteiden kohdalle juuri oikealla hetkellä, vaan vasta hieman liian myöhään.

Prosesseja hidastavia ja toimintahäiriöitä aiheuttavia tekijöitä pyritään estämään, mutta käytännössä tuotantohäiriöiden ennakointimahdollisuudet ovat rajalliset, jos koko kriittistä laitekantaa ei pystytä valvomaan tehokkaasti reaaliajassa.

Teollisuuden kunnossapidon suurimmat haasteet

Onko siis teollisuuden prosessien käyttövarmuuden ja tuotantotehokkuuden lisääminen saavuttanut päätepisteensä? Ei onneksi, mutta haasteita kyllä löytyy taklattavaksi – ja ”perinteisten” kiinteiden kunnonvalvontajärjestelmien kustannustehottomuus on niistä vain yksi.

Hintalappuakin suurempi haaste voi olla perinteisen järjestelmän kankeus. Käytännössä kaikkia kriittisiä pisteitä ei pystytä valvomaan, koska perinteistä järjestelmää ei voi laajentaa joustavasti tarpeiden mukaan. Useimmat järjestelmät eivät noudata samoja teknisiä standardeja eivätkä ole keskenään yhteensopivia, mikä sitoo tietyn järjestelmän käyttöön.

Kokemuksiemme mukaan kolmas selkeä haaste on kiinteällä anturikaapeloinnilla toteutettujen kunnonvalvontajärjestelmien vikaantumisherkkyys, joka myös osaltaan altistaa virhetilanteille ja mahdollisille tuotantokatkoksille.

Ennakoivalla kunnossapidolla seisokit minimiin ja tuotantokatkokset hyötykäyttöön

Prosessien aika-hyötysuhde saadaan nousuun ainoastaan ennakoimalla potentiaalisia vikatilanteita mahdollisimman tehokkaasti. Ennakoivan kunnossapidon avulla saadaan paitsi seisokkiajat minimoitua, myös suunnitellut katkokset kuten tehtaiden vuosihuollot parhaaseen mahdolliseen hyötykäyttöön. Jos huoltotoimenpiteiden todellinen tarve ei ole tiedossa etukäteen, ei suunniteltuja tuotantokatkoksia ole mahdollista ajoittaa niiden mukaan.

Tuotantotehokkuuteen vaikuttaa myös se, miten optimaalisesti prosessin säädöt toimivat muuttuvissa tilanteissa. Teollisuuden automatisoiduissa prosesseissa on tuhansia erilaisia muuttujia, jotka edellyttävät prosessioperaattoreilta ohjaustoimenpiteitä. Mitä enemmän tietoa laitteiden todellisesta kunnosta voidaan tuoda operoinnin tueksi, sitä paremmin myös muuttuviin tarpeisiin voidaan vastata.

Uudenlaista ajattelutapaa ja teknologiaa siis tarvitaan. Mitä nopeammin ennakoivaan teollisuuden kunnossapitoon siirtyy, sitä enemmän alkaa myös jäädä viivan alle.

Miten teollisuuden kunnossapitoa voi tehoistaa ulkoistamalla? Lue lisää!


Caverionin asiantuntija Risto Leisti

Risto Leisti
Johtaja,
Kunnossapidon Kumppanuudet

Caverion



Julkaistu 10. lokakuuta 2017






447 comments

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