According to the Digital Observatory of Health and Occupational Safety,Brazil is in fourth place in the world when it comes to work accidents. There are about 700,000 of them a year, which is equivalent to one accident every 45 seconds during office hours. Alarming data such as these led the Ministry of Labor and Employment (MTE) to create the Regulatory Standard NR:12, which aims to ensure the safety of equipment, both for the benefit of employees and employers.
This standard is one of the most important of the Consolidation of Labor Laws (CLT) and has been undergoing several updates over the years. The latter took place through Ordinance No. 916of the Ministry of Economy, which entered into force in July 2019. For this reason, it is essential that organizations know the guideline, which covers the entire life cycle of machines, optimizing safety and minimizing losses.
Follow our post and learn more about it!
What is NR:12?
NR:12 is the acronym for Regulatory Standard Number 12 that, as we mention, aims to ensure basic safety standards for the work environment of employees who work in the assembly and operation of equipment of various natures, such as industrial and agricultural.
According to what is contained in an excerpt of the standard itself, which is even one of the most extensive of the CLT, it and its annexes: “define technical references, fundamental principles and protective measures to ensure the health and physical integrity of workers and establishes minimum requirements for the prevention of accidents and occupational diseases in the design and use phases of machinery and equipment of all types, as well as their manufacture, import, marketing, exposure and assignment to any
Why should your company fit in?
First, it is essential that organisations take part in NR:12 because of the problems that accidents at work can cause to both the employee and the employer. The following are the main reasons for prioritizing compliance with the standard:
A simple oversight related to the maintenance of equipment is capable of causing serious damage to individuals, who may be left with limitations. Families are also affected, after all, often depend on these people for survival.
Not to mention that fatal accidents are capable of causing irreparable emotional problems, as well as severely compromising the lives of family members in addition to negatively weighing on the company’s image.
The financial aspect reaches all involved. For starters, the employee often maintains family income and becomes unable to continue working if he suffers an accident.
The entrepreneur, in turn, needs to pay compensation, lawsuits, among others. Not to mention the reputation in the market and in society, which can harm the operation and continuity of the company.
Another relevant point is the Brazilian economy as a whole, since it is directly impacted by costs related to removals and with productions harmed or interrupted.
Judicial and bureaucratic factor
Complying with NR:12 is not only a matter of choice by organizations, but an obligation that, if not fulfilled, can generate fines, notifications, assessments and interdictions. In addition, there are numerous lawsuits in court that discuss compensation related to work accidents.
It is important to emphasize that, in addition to unexpected circumstances, there are incidents caused on purpose by workers, who aim to receive unduly compensation or other types of benefits. Strange as it may seem, NR:12 also aims to protect employers in this regard.
What should the suitability of regulatory standard NR: 12 be on the lookout for?
The need for adaptation to NR:12 involves all areas of an industry that operate equipment capable of causing accidents. The company’s planning should establish processes, responsibilities and training of equipment operators, as well as the work safety team, which includes contracted or outsourced employees.
The program to be developed should also describe all activities related to the application of machinery protections, inspections, team responsibilities, safe working practices, record maintenance and training requirements. To be clearer, check out some important points for suitability:
- equipment protections must have a physical barrier that makes it impossible for the operator to place any part of the body in the risk zones during their cycle;
- tamper-proof protections, so that they cannot be removed or tampered with by employees;
- equipment should be immediately removed on the ipending of any risks. To do this, employees must have access to devices that can be triggered emergencyly;
- the lubrication of the machines of preference should be done without the employees having to take away the proper protections;
- interfere not with the operation of the equipment under any circumstances.
There are several details to be observed by organizations that intend to act according to NR:12 and thus offer a safer environment to all teams.
How to suit NR: 12?
The first step of adequacy to NR:12 should be a preliminary analysis of the inventory of equipment and its risks, in order to consider the most common scenarios and implement concepts such as “safe failure”, which consists in minimizing or eliminating the risk even in cases of malfunction. That is, the machine can enter a safe mode that provides protection to workers in the event of performance failures.
Other important aspects are administrative aspects, which include policies, procedures and work safety instructions, in addition to the provision of appropriate Personal Protective Equipment (PIs) for each type of activity.
The standard can be implemented for new equipment projects or on systems already in the organization. For this, it is possible to count on the help of specialized companies, which provide guidance and assist in the development of important procedures for the adequacy to NR:12.
Did you know that Nalbatech works with the best automation solutions that allow your company to tailor to NR:12? If you want to meet. If you want to know them, please contact us and schedule a meeting. We will be delighted to serve you!
Preventive maintenance planning,, increasingly important for companies seeking agility and productivity is a competitive differential in an increasingly crowded market. It seeks to avoid problems that cause the fall in performance or failures in equipment that negatively compromise production.
Not to mention that periodic and scheduled inspections contribute to the safety and motivation of teams, increased machine life and reduced costs related to repairs and emergency exchanges.
It was thinking of raising the business’s awareness about the subject that we developed this article. Follow along and learn why maintenance is so essential to your business!
Preventive maintenance planning: what is it?
As the name suggests, preventive maintenance planning aims to correct equipment failures even before they occur, in order to reduce production interruptions and consequent losses. In practice, these are inspections made at periodic intervals, following a pre-established plan.
According to ABNT’s NBR 5462, this type of maintenance consists of the combination of all technical and administrative actions, which include scans, which aim to maintain or reset a machine, so that it can play the desired role.
To make maintenance planning, you can choose between different parameters or join them and thus determine the most appropriate periods. They are:
- time: determines the interval at which preventive maintenance should be performed, for example, every six months, regardless of the presentation of failures;
- productivity: establishes the timing of inspections according to operation cycles or number of items produced;
- operating hours: Takes into account the hours when the equipment was actually active during a certain period.
With these defined aspects, it is important that the company develops an inventory with all the fundamental points for the process. The document should contain, for example, the machines that should be prioritized, the activities to be carried out, the service managers and the specific dates for the development of the actions.
Thus, teams can prepare for possible stops, rather than being unexpectedly surprised, which brings damage to the business.
What are the advantages of preventive maintenance planning?
Investing in preventive maintenance brings a number of benefits to organizations. For starters, the action prevents failures that could generate high costs if not avoided. Here are other important advantages:
Quality of operation
That preventive maintenance assists in the proper functioning of the equipment you already know. However, it is important to emphasize that the strategy directly contributes to a company’s reputation.
To be clearer, imagine the following situation. You have a factory and have proposed a certain deadline to the customer. However, due to failures in a machine, what was combined between the parts was not fulfilled and the customer was left without the product in stock.
As can be imagined, this situation would be quite negative for the business, both in relation to the unattended partner and its image in the market, since the opinions resonate quickly and are taken into account more and more.
Reduction in resource waste
For a company to grow, there must be profit. This, in turn, depends on a series of actions by managers, such as the development of actions that minimize the waste of resources. In this scenario, preventive maintenance is an excellent tool.
This is because, through a well-structured inspection planning, combined with the use of adequate systems and the performance of qualified professionals, the company better manages its assets. So she can employ the budget intelligently.
That is, it is possible to do research of the best suppliers and act in a timely manner to avoid exorbitant expenses with corrective maintenance. After all, as we know, technical visits and emergency maintenance tend to cost much more than preventive services.
Contribution to job security
Problems with equipment are able to bring from simpler to more serious damage. This includes accidents with employees during machine operation, which can trigger lawsuits, damage to the image of the business, penalties and fines related to work safety.
Through constant maintenance this does not occur. In addition, employees working in a safe environment feel more motivated and, consequently, produce more.
Why should your company adopt this type of maintenance?
As high-quality as a piece of equipment is high, frequent wear and tear on parts, which may be defective over time. This is a natural situation, which is linked to the use of the machine. However, despite this, it is common for industrys suffer unexpected stops due to lack of inspection in its assets.
It is precisely in this scenario that preventive maintenance comes in. Although some think it is a cost, scheduled inspections are actually an investment. This is because organizations no longer have excessive spending on corrective maintenance, while the investment is less than in predictive maintenance, which relies on integrated systems and sensors to occur.
How can Nalbatech help?
Now that you know the concept and importance of preventive maintenance planning for your business, you may be wondering how to implement the strategy in practice. In this case, it is possible to count on Nalbatech.
Through specialists, your company will have technological and robust solutions to assist in various aspects, including maintenance planning. All focused on your business.
In practice, this will mean more business intelligence and agility of action in the hands of managers and operators, causing your company to reduce costs and grow in the market.
Did you like our content? Want to know more about all Nalbatech solutions for your business? So contact us right now, we will be very pleased to serve you!
Preventive Maintenance. This is an increasingly sought-after solution by organizations looking to perform at the highest cost. This is because it aims to prevent equipment failures, so that the operation is continuous and it is not necessary to bear repairs and emergency changes.
Today, more than necessary, anticipating problems and keeping the company with high performance has become a fundamental issue, since the market expects agility, competition is high, customers are demanding and expenses must be controlled to minimize losses.
If you’ve come this far, it’s probably because you’re interested in getting this and other differentials brought by proactive conduct. In that case, you’ve come to the right place. Follow our article and learn all about it!
Learn more about Preventive Maintenance
According to NBR 5462,of the Brazilian Association of Technical Standards (ABNT), preventive maintenance is the set of technical and administrative actions with the objective of reducing the probability of failure or degradation of the operation of an item.
In practice, the processes take place through the planning of periodic inspections on various types of machinery and equipment,whether industrial, automotive, hydraulic, among others. Some results, in this case, are the conservation of assets, the safety of workers, customer satisfaction and the economy.
The issue of maintenance in times of Industry 4.0
Preventive maintenance is a concept that began in the 1950s, between the Period of World War II and post-war, when the sector realized the need to ensure reliability and availability of assets while maintaining productivity. Since then it has been used to restore the original conditions of the equipment, before potential failures arise.
Like countless other processes, this has undergone significant changes from industry 4.0 technologies. Today, what is expected is to perform an increasing number of maintenance activities, with increasingly optimized features.
For this, technological resources such as artificial intelligence and internet of things (IoT) are used, which help in the insertion of the future element, enabling us to have answers to situations that have not yet occurred, but would if no action were taken.
One of the concepts of Industry 4.0 is the creation of a virtual model of the machines and the entire production system, so that it is controlled and can be operated remotely. This is facilitated with the use of sensors, which send the control software the situation of each equipment. The system, which allows the detection of irregularities in real time, can be based on preventive maintenance, corrective maintenance and predictive maintenance.
Corrective maintenance x preventive maintenance x predictive maintenance: understand the differences
As we mention, industrial maintenance is composed of three methods, which are applied at different times, as well as bring different results. To make you understand each of them better, here’s what they’re all about:
- Preventive maintenance: aims to reduce failures or falls in machine performance through a pre-elaborated schedule in which periodic inspections are included;
- Predictive maintenance: actsin the routine inspection of equipment to identify abnormalities that may cause problems. This periodic monitoring is used by data collected through monitoring or inspections. The most used techniques are vibration analysis, ultrasound, visual inspection and non-destructive analysis techniques.
- Corrective maintenance: Occurs when a fault is already detected and activities occur in an unscheduled manner. As can be imagined, in this case there may be interruption in activities and unexpected costs due to the actions carried out in an emergency manner.
From what you have been able to prove, you need to have an adequate maintenance planning, which includes preventive maintenance, to avoid losses, to the same extent that you get better results.
The importance of preventive maintenance for your organization
It is possible that you have already heard the saying “the cheap that comes out expensive”. It applies well when it comes to lack of maintenance in an organization. After all, when inspections are seen as a cost and not an investment, the company ends up spending exorbitant amounts with unexpected failures.
In addition, equipment that is not reviewed periodically may have loss in performance without demonstrating, requiring a higher expenditure of electricity, for example.
When the organization invests in preventive maintenance, the scenario is just the opposite. In this case, some advantages are:
- ensures maximum use of the life of the machines;
- optimizes resources for reasons such as having more time to search suppliers, lower costs of repairs and parts changes, and minimizing overtime by unexpected stops;
- quality of the operation, since production is carried out on time and, consequently, customers are satisfied;
- prevention of accidents at work, ranging from the simplest to the most serious, capable of bringing incalculable damage.
With these factors, it is clear the importance of this type of maintenance to decrease the probability of failures. But in order to be advantageous and make sense for the company, it needs to beused strategically, based on well-structured planning and the best partnerships and tools.
To help companies perform preventive maintenance and their other subtypes efficiently, Nalbatech provides SAN Mobile, a platform that helps teams perform consultations, updates, data release and order confirmation in real time, 100% compatible with SAP® PM module.
This brings process automation securely and simply, all in user-friendly, fast and intuitive interfaces, so companies minimize errors and reduce time spent on highly transactional processes.
We hope that our article will help your organization to rely on well-structured maintenance processes. Interested in knowing Nalbatech’s solutions for process automation? So contact one of our expertsright now!
Preventive maintenance management is essential when planning the maintenance of a company’s equipment, as it avoids major downtime in production and, consequently, waste of money. In addition, it is an essential item when it comes to safety and conservation of these essential tools in a factory.
In summary, the process aims to avoid machine failures and breakages during operation. It is a set of applied actions that seek to avoid the costs of purchasing new equipment. In addition, preventive maintenance helps to optimize expenses with corrective maintenance on equipment.
However, it does not recover equipment from failures, but rather prevents it from occurring during operation, also avoiding risks and wear on equipment. Thus, maintenance is carried out through periodic reviews of the parts and components of the operation.
According to the NBR-5462, maintenance is performed at predetermined intervals and corresponds to three types: corrective maintenance, preventive maintenance and predictive maintenance. What differentiates one from the other is the type of strategy adopted to keep the equipment available and safe.
The difference between preventive and predictive maintenance
Always keeping preventive and predictive maintenance up to date is a constant challenge for managers. In fact, a standstill equipment represents many costs of replacing parts, in addition to the loss of time with the interruption of production.
On the one hand, corrective maintenance consists of the immediate resolution of a problem caused by equipment, often unscheduled, which can cause enormous damage to the business. Corrective maintenance management is what ensures that unforeseen high costs are avoided.
On the other hand, preventive maintenance has the role of monitoring and controlling possible failures that occur in the performance of machines and equipment. This type of action is always planned and carried out periodically, within an operating schedule stipulated in the management of corrective maintenance. Generally, the manufacturer advises on the appropriate time for each equipment supervision to be done. This strategy is carried out regardless of whether the damages are presented or not.
Predictive maintenance is very similar to preventive maintenance. The difference is in the process of systematic inspection and compliance with the change in performance conditions and equipment parameters. That is, the action takes into account the analysis of the operation of the machines and equipment, without being scheduled in any schedule. When the monitoring professional identifies any performance problem, the planned corrective prevention is performed.
Types of preventive maintenance
There are many types of maintenance, however, with well-designed preventive maintenance management, two categories are regularly used: time-based preventive maintenance and usage-based preventive maintenance.
Time-based preventive maintenance
This type of maintenance consists of repairing or replacing parts of a machine or equipment based on a fixed interval of time. Regardless of whether the machine is working or not, the exchange is carried out, aiming to guarantee the safety and the proper functioning of the equipment without jeopardizing the production and the work flow in case of stoppage.
Preventive use-based maintenance
Usage-based preventive maintenance is performed after a specified number of hours of use, production cycles or mileage. For example, every 200 cycles or 15 thousand hours of use, maintenance is performed as a way to also avoid an unexpected stop in production to perform corrective maintenance on an emergency basis.
Or, in a more practical way in our day-to-day, the factory recommends that a car is revised every 10,000 kilometers, regardless of whether it has flaws or not, for example.
How to carry out maintenance management effectively
Even with the efficiency of the maintenance processes in correcting any problem in the equipment or machines as quickly as possible, there is a need for more efficiency in keeping everything running smoothly. Companies that do not work with good maintenance management, end up only putting out fires, worrying only when the equipment or the machine is already damaged.
This causes an even greater cost, in addition to delays in the production process. Therefore, numerous tools have emerged that contribute to the best maintenance results. As we have already mentioned, it is essential that preventive maintenance management be carried out, so that everything is properly planned.
This avoids unnecessary or urgent downtime for parts replacement or maintenance. This planning also avoids unforeseen events and wasted time. But what is the best way to manage effectively? Check out the tips we’ve separated below.
Define the best type of maintenance to be performed
First of all, it is very important that a diagnosis related to the structure and needs of a company is prepared to choose the best type of maintenance to be applied. Generally, the most used options are predictive or preventive maintenance. In addition, there may also be a plan in which the two types are carried out together.
The diagnosis can be made with the help of a service provider company specialized in this type of analysis. Business managers and owners should also participate, ensuring that the best alternatives are defined based on the context of the company.
Perform due control of maintenance costs
Managing maintenance costs is essential for any organization, especially in such a competitive market, in which managers seek more efficiency in production with ever lower expenses. Budget optimization is a differential that guarantees lower product prices.
Therefore, it is essential that maintenance be able to measure its costs through the management of preventive maintenance. In fact, maintenance plays a fundamental role in raising all costs through programmed planning, outsourced labor records and control of basic operating expenses, such as parts and own labor.
In order for the plan to be managed effectively, it is important to get rid of the countless spreadsheets used so far, and migrate to software that does this management automatically. The systems available on the market are capable of managing investments made at each stage, from scheduling maintenance to purchasing parts and services used.
With this process it is possible to optimize and monitor from the costs of the simplest to the most complex activities, even allowing for future visibility of maintenance expenses.
Analyze maintenance performance
Every good preventive maintenance management has a constant performance analysis. In other words, there is no point in wasting time planning if the effectiveness of the plan is not being guaranteed. Este tipo de análise garante que o plano seja revisado caso algo não esteja funcionando corretamente dentro do cronograma de atividades. But how to make this measurement?
The analysis can be done by extracting data based on the information collected by the technicians who perform the maintenance. The most important indicators are related to the asset’s real costs and the decision-making power that these data can allow.
For the indicators to be implemented, it is necessary to have a system for collecting and dealing with the data. These numbers can be tracked using the maintenance software. With the system, the indicators will be generated automatically and efficiently.
Plan preventive and predictive maintenance
Planning preventive and predictive maintenance is the basis of all effective management, as it reduces and prevents the breakdown of equipment and machines. However, drawing up a plan is a major challenge for professionals working in this area. In this case, as we mentioned earlier, software is very useful and helps to optimize preventive maintenance management.
There is a great difficulty in tracking maintenance data manually, since they are activated after a certain period or use in many critical equipment, making this monitoring difficult. A maintenance system is able to create a service order, based on appropriate triggers for each registered equipment.
Use maintenance process management systems
New technological tools can be essential for good planning. It is not new that there are several software specialized in the management of preventive maintenance. The solutions are focused on improving the operational efficiency of the industry. In fact, they are very effective in control and planning and allow easy integration with other systems such as ERP.
With a system it is possible to:
● Gather data;
● Issue alerts;
● Plan services;
● Create event history;
● Ensure greater stability;
● Higher productivity at the factory;
● Security in accessing information;
● Reduction of administrative and operational costs;
● Faster and more organized processes, also generating improvements in the flow of information. Faster Traduções de faster AdvérbioFrequência mais rápido faster mais depressa faster Sinônimos de faster Advérbio quicker Veja também fast
Control inventory and tools
A good preventive maintenance management has all the control of stock and tools used in the process. In fact, this means that problems can be corrected instantly, avoiding long stops if the tools are not available in stock.
With this control, it is also possible to easily find the location of each part required for maintenance. On the other hand, knowing which parts are available, what quantity is available and where they are located, optimizes time, reduces costs and increases productivity.
Therefore, it is important that a thorough check is made, with records of the date of withdrawal and return of each item used. This control can be done using a term of responsibility signed by each person who uses the tools or removes the parts.
Advantages of preventive maintenance management
Many managers do not understand the importance of a process and the real need for it for the proper functioning of the business or the production of an industry. Therefore, we list the main benefits of having a well planned maintenance management.
A poorly organized maintenance plan can interrupt processes and delay production, causing losses to the business. For this reason, good planning is essential for maintenance to happen with a schedule to stop the equipment. In addition, it is important to define the need for employees working on this process, ensuring that the company loses less money while investing in unnecessary time.
Compliance with laws and regulations
It is very important that the maintenance manager is aware of all laws and regulations that permeate this type of process, because if there is inspection during maintenance and the work does not comply with safety laws, the company may be fined.
Control of expenses
With preventive maintenance management, it is possible to keep under control all expenses generated with the maintenance of machines and equipment. Good planning also ensures that the budget defined for this area is better used, since the maintenance manager can decide on the supplier with the best cost benefit.
An efficient planning works with the scheduling of tasks well defined in the schedule. However, it is necessary to know and understand the relative priority of equipment and machines.
With a good preventive maintenance plan, it is possible to reduce a lot of waste in a factory, such as labor, time and materials. If the activities are not planned through the implementation of systematic procedures, there will certainly be a lot of waste of maintenance time. In addition, production will also not need to be stopped at a time that is in full swing, simply to perform maintenance that may not have been necessary at that time.
Now that you know the benefits and the importance of conducting preventive maintenance management effectively, how about starting to plan for your company? Get in touch with Nalbatech and find out how we can help you!