With its experience in technical services in corrective & preventive maintenance as well as technical check-ups, STERIGENE developed a predictive maintenance service for your pharmaceutical process equipment.
Predictive maintenance reduces the probability of failure of your equipment
Maintenance has become a major factor in the control of production tools and now has a preventive role in ensuring the good working order of the production systems. According to the French standard NF EN 13306 X 60-319, maintenance is defined as: “the set of all technical, administrative and management activities throughout the life cycle of a property, carried out so as to maintain or restore it to a state in which it can perform the required function”
Appendix A of the standard NF EN 13306 X 60-319 of June 2001
Preventive maintenance takes place before the detection of a failure. To meet both the needs of its customers and the market, STERIGENE goes even further by offering predictive maintenance adapted to the specific use of your pharmaceutical process equipment.
STERIGENE’s predictive maintenance service can:
- Act on the faulty component closest to its expected dysfunction period.
- Track deterioration in the event of a variable life expectancy of an element.
- Reduce the frequency of outages, while optimising the frequency, duration and cost of preventive operations.
A proven predictive maintenance method
Predictive maintenance is based on a targeted maintenance of components defined by a wear threshold and is controlled depending on the parts of the process equipment. Several criteria used to reduce the probability of failure are considered: uptime, number of activations, vibration levels…
STERIGENE has implemented a method for predictive maintenance in 4 steps:
1. Define what to look for by type of equipment, its options and its settings:
• By criticality, impact on the process, replacement cost, frequency of use / operation
2. Establish the monitoring methodology to be applied:
• Item activation counter (eg. for each cycle, count or estimate the number of valve operations), running time counter (motor / pump)
• Exposure time counter (eg. contact time of a gasket / membrane to temperature and / or pressure)
• Process data (eg. evolution of the time taken to achieve vacuum)
3. Establish thresholds and the alert method:
• Compared to the manufacturer/designer data
• Compared to statistical data / experience
• Compared to functional data
4. Analysis of preventive & curative operations in parallel:
• Identification of areas for improvement over the cycle analysis reports
Results for STERIGENE’s predictive maintenance service:
Optimisation of systematic maintenance into a lighter and more focused maintenance with the following objectives:
1. Reduced MTBF (mean time between failures) by 15% by matching the items requested by the process and those changed preventively
2. MRT / MDT reduction by 25% thanks to a better focus of the action only on the elements to be changed (reduction in the duration with increase of the frequency)
3. Reducing the cost of parts (15%)
>> Apart from the results achieved, several induced effects are visibly established when this method is chosen. Indeed, changing maintenance practices towards more “upstream” focus allows to initiate multi-thematic reflections integrating operational quality, production and maintenance teams. Indeed, the implementation of this approach is often accompanied by:
- The drafting of new maintenance specifications to consolidate the practices;
- The incorporation of component operational quality by improving the traceability of interventions;
- A better integration of everyday problems encountered by users and logging them in a continuous improvement of equipment availability rates;
- The setup, thanks to investigations conducted on the equipment and the monitoring of its performance, and initiate a more comprehensive reporting of the machine to the technical directorate.
Les prestations techniques de STERIGENE concernent la gestion complète de votre parc machine, la définition et la constitution du stock de pièces détachées, le conseil et l’assistance technique dans le cadre de contrat orientés objectifs. Contactez-nous dès maintenant pour en savoir plus :
Vous dépendez de GENItec NORD, contactez-nous par mail au service.nord@sterigene.com ou par téléphone au 01 34 44 23 30.
Vous dépendez de GENItec SUD, contactez-nous par mail au service.sud@sterigene.com ou par téléphone au 04 37 41 10 42.