Theo kết quả của cuộc khảo sát năm 2020 về các đặc thù bảo trì công nghiệp của tổ chức Plant Engineering thực hiện tại Mỹ đã nêu bật những điểm chính của bảo trì 4.0 hiện nay như sau:
88% các DN sản xuất tại Mỹ ưu tiên thực hiện chiến lược bảo trì phòng ngừa;
52% DN đã triển khai hệ thống quản lý bảo trì bằng máy tính (CMMS) vào công tác quản lý bảo trì.
Tuy nhiên vẫn có 51% DN sản xuất tại Mỹ vẫn còn sử dụng phương pháp chạy đến hỏng hóc.
46% các DN dành đến 10% chi phí hoạt động hàng năm cho quy trình bảo trì;
41% dành hơn 10% ngân sách này cho bảo trì.
Trung bình, mỗi DN dành 33 giờ/tuần cho bảo trì định kỳ, (tăng 13 giờ so với 20 giờ theo dữ liệu năm 2019).
Thiết bị sản xuất, thiết bị quay (động cơ, truyền động, v.v.) và hệ thống truyền động chất lỏng (khí nén, thủy lực, v.v.) là ba khu vực được hỗ trợ bảo trì nhiều nhất, tiếp theo là thiết bị xử lý vật liệu và hệ thống phân phối điện nội bộ.
88% các DN thuê ngoài một phần hoặc toàn bộ hoạt động bảo trì; Trong đó trung bình, mỗi DN thuê ngoài 23% hoạt động bảo trì. Nguyên nhân chính dẫn đến việc thuê ngoài là do có thỏa thuận với nhà sản xuất hoặc nhà cung cấp, thiếu kỹ năng trong đội ngũ hiện tại và thiếu thời gian/nhân lực cho bảo trì.
Nhân viên bảo trì chủ yếu được đào tạo về kỹ năng cơ bản cơ khí và điện/điện tử, cũng như an toàn. Các loại đào tạo khác bao gồm động cơ, hộp số, vòng bi và bôi trơn.
Các công nghệ phổ biến nhất để giám sát và/hoặc quản lý bảo trì là: CMMS, bảng tính/lịch trình do nội bộ tạo ra và lịch trình bảo trì tự động.
Nguyên nhân hàng đầu của ngừng máy đột xuất tại các DN công nghiệp là thiết bị cũ, tiếp theo là hỏng hóc cơ học, lỗi của người vận hành và thiếu đào tạo phù hợp. Hơn một nửa các DN đang có kế hoạch nâng cấp thiết bị để giảm thiểu gián đoạn không lên kế hoạch.
Thách thức lớn nhất để cải thiện bảo trì tại các DN công nghiệp là thiết bị cũ. Các trở ngại khác bao gồm thiếu hiểu biết về các tùy chọn và công nghệ mới, thiếu nguồn lực hoặc nhân lực và công nghệ lỗi thời.
48% các DN cho phép sử dụng các thiết bị kết nối để giám sát thiết bị sản xuất nhằm thu thập, phân tích dữ liệu máy móc và cải thiện các hoạt động bảo trì, kỹ thuật và/hoặc công nghệ vận hành/thông tin (OT/IT).
Công nghệ Internet Vạn Vật Công Nghiệp (IIoT) và các công nghệ liên quan đã giúp các DN hiểu rõ hơn về tình trạng máy móc, cải thiện độ tin cậy và dự đoán cũng như ngăn ngừa hỏng hóc thiết bị hiệu quả hơn.
Nguồn: CFE Media and Technology/Advanced Technology Services (ATS)
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