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Advisor(s)
Abstract(s)
O aumento da competitividade industrial e a procura pela gestão de excelência proporcionaram a busca incessante por novas estratégias de gestão, estratégias essas que proporcionassem o aumento da eficácia e da eficiência dos sistemas produtivos das empresas. A manutenção é uma das áreas que promove o aumento destes parâmetros e possibilita a redução de paragens não programadas, a maior disponibilidade de equipamentos, a redução de custos e o aumento da produtividade. No entanto, o estudo da manutenção potencializou o aparecimento de novas abordagens mais focadas na fiabilidade e na monitorização da condição dos equipamentos, como é o caso da manutenção preditiva. A presente dissertação tem como objetivo a implementação de manutenção preditiva em bombas de vácuo de anel líquido, na empresa ATEP – Amkor Technology Portugal, S.A.. O estudo baseou-se na criação de dois sistemas de monitorização da condição das bombas de vácuo de anel líquido e no desenvolvimento de planos de manutenção preventiva para estes equipamentos. O primeiro sistema implementado permitiu analisar a aplicação de sensores de baixo custo através da linguagem de programação Arduino, funcionando como um sistema offline. Por fim, o segundo sistema implementado consistiu na aplicação de sensores de melhor qualidade permitindo assim, recolher dados relevantes acerca do normal funcionamento do equipamento para posteriormente prever o momento de ocorrência de falha e/ou avaria. Com isto, deu-se o aprimoramento das ações de manutenção, otimização dos indicadores-chave de desempenho, redução de custos associados à manutenção e garantia da qualidade do produto final. No sistema offline reduziu-se 67% o MTTR, 88% o período máximo de manutenção, em 31% o período mínimo de manutenção e 40% os custos de manutenção. No sistema online, o MTTR reduziu 63%, os custos de manutenção reduziram 56% e os períodos máximo e mínimo de manutenção reduziram 92% e 23%, respetivamente.
The increase of industrial competitiveness and the search for excellence in management provided the incessant demand for new management strategies, strategies that would increase the effectiveness and efficiency of the companies production systems. Maintenance is one of the areas that promotes the increase of these parameters and enables the reduction of unscheduled stops, the greater equipment availability, costs reduction and the increase of productivity. However, maintenance study potentiated new approaches emergence more focused on reliability and on condition monitoring of equipment, such as predictive maintenance. This dissertation aims to implement predictive maintenance on liquid ring vacuum pumps, in ATEP – Amkor Technology Portugal, S.A.. This study was based on the creation of two systems to monitor liquid ring vacuum pump condition and development preventive maintenance plans for these equipments. The first implemented system allowed analyzing the application of low-cost sensors through Arduino programming language, working as an offline system. Finally, the second system implemented consisted of the application of better quality sensors, thus allowing relevant data collection about the normal operation of the equipment to later predict a failure and/or breakdown moment. As a result, maintenance actions were improved, key performance indicators were optimized, maintenance costs were reduced and the product final quality was guaranteed. In offline system, MTTR was reduced by 67%, the maximum maintenance period by 88%, the minimum maintenance period by 31% and maintenance costs was reduced by 40%. In online system, MTTR reduced by 63%, maintenance costs reduced by 56% and maximum and minimum maintenance periods reduced by 92% and 23%, respectively.
The increase of industrial competitiveness and the search for excellence in management provided the incessant demand for new management strategies, strategies that would increase the effectiveness and efficiency of the companies production systems. Maintenance is one of the areas that promotes the increase of these parameters and enables the reduction of unscheduled stops, the greater equipment availability, costs reduction and the increase of productivity. However, maintenance study potentiated new approaches emergence more focused on reliability and on condition monitoring of equipment, such as predictive maintenance. This dissertation aims to implement predictive maintenance on liquid ring vacuum pumps, in ATEP – Amkor Technology Portugal, S.A.. This study was based on the creation of two systems to monitor liquid ring vacuum pump condition and development preventive maintenance plans for these equipments. The first implemented system allowed analyzing the application of low-cost sensors through Arduino programming language, working as an offline system. Finally, the second system implemented consisted of the application of better quality sensors, thus allowing relevant data collection about the normal operation of the equipment to later predict a failure and/or breakdown moment. As a result, maintenance actions were improved, key performance indicators were optimized, maintenance costs were reduced and the product final quality was guaranteed. In offline system, MTTR was reduced by 67%, the maximum maintenance period by 88%, the minimum maintenance period by 31% and maintenance costs was reduced by 40%. In online system, MTTR reduced by 63%, maintenance costs reduced by 56% and maximum and minimum maintenance periods reduced by 92% and 23%, respectively.
Description
Keywords
Manutenção Manutenção Preditiva Manutenção Baseada na Condição Manutenção Centrada na Fiabilidade Sensorização Indústria 4.0 Maintenance Predictive Maintenance Condition-Based Maintenance ReliabilityCentered Maintenance Sensorization