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Preventive measures

Preventive measures: the solution to avoid production stoppages

Any breakdown triggers a period of crisis. This may be more or less significant and may have three serious consequences:

  • Economic impact: A shutdown of the production line results in a significant financial loss for your company.
  • Environmental impact: A breakdown can lead to environmental risks such as river pollution, toxic vapour being discharged into the atmosphere, etc. A simple breakdown can lead to an ecological disaster.
  • Human impact: Any emergency situation creates confusion and hence poses a danger to people’s safety.

It being understood that the human or ecological impacts are unacceptable, our attention will focus on the economic aspect.

The criticality of the impact is adjusted according to the maintainability of the system (outdated system), funnel effects and production requirements.

The focus is therefore essentially financial, taking into account production requirements, the MTBF of the product and also its MTTR, and ensuring both the technical interest and the capacity to enhance the reliability of the product.

The goal of preventive action is therefore to implement a measured action leading to economic gain through the reliability of the production system. Discussions must therefore take into account:

  • The system failure rate (maintenance rate and risk rate)
  • MTBF of the new product
  • MTTR of the product
  • The economic impact on production

Analysis of these four criteria will enable us to come up with a proportionate response to the economic risks incurred.

Key

figures

% reduction of your breakdown rates

sites

expert technicians

hours of work

Preventive measures at DV Group

A solution tailored to all your electronic power components

The handled products include the entire range of products repaired by DV GROUP.

Our services may be limited to workshop upgrades or consider the full range of your needs (disassembly, backup, reassembly, etc.).

DV Group is also able to support you in your decision by offering you the ability to identify the risk rate on your large drive network.

This monitoring allows you to set out a calculated risk rate and a quantified solution resulting in an identified reduction to this risk.

DV GROUP helps you manage your fleet

DV GROUP can offer you a preventive solution to improve the availability of your production tools.

By implementing of these preventive solutions for your electronic and/or electromechanical resources, the MTBF for your products is enhanced.

DV GROUP provides you with both technical skills and packaged solutions:

  • Prevention: on-site preventative measures without dismantling specialist equipment (measurements, backup, etc.)
  • Corrective prevention: equipment modified in the DV GROUP workshops (clean-up, change of capacity, etc.)
  • Technological audit: DV GROUP experts analyse the technologies associated with your process and define the equipment, procedures and solutions necessary to ensure its ongoing availability

Our preventive maintenance service involves the use of many tools, including:

  • HUNTRON signature analysis
  • Digital Oscilloscope
  • Clamp ammeter
  • Tachometer
  • Mega Ohmmeter
  • Thermal camera
  • LCR high voltage meter
  • Curve tracer
  • Data acquisition unit (network analysis unit)
  • Digital processing, modelling and expertise software

Case study :

CLAIREFONTAINE

Need / Context

To secure the site's critical machine, Clairefontaine entrusts us with preventative measures for the sectional design of the paper making machine composed of 18 Masterdrives (8 of 250 KW and 5 of 75 KW). Our intervention aims to avoid any unplanned production stoppages that would be costly for the site, given that the machine’s production speed can reach 1,000 metres per minute (i.e., 60 kilometres and 15 tonnes of paper per hour).

Solutions

We recommend regular preventive maintenance of variable speed drives throughout their life cycle as part of your maintenance schedule. The aim is to ensure maximum efficiency and minimum costs for unforeseen repairs. Our corrective preventive measures consist of reconditioning the product, in-depth cleaning, and the individual analysis of each component, including, if necessary, their replacement. As for all of our procedures, the reconditioned variable speed drive undergoes full testing. Procedure: - Clean-up. - Upgrade. - Thermal and endurance testing. - Change of critical components: - Ventilation - Capacity of the intermediate bus - Overhaul according to SIEMENS manufacturer specifications and procedures DV is the only accredited “Powerblock” repairer in Europe. We are currently the only accredited “Powerblock” repairer in Europe. This certification means that we are authorized by Siemens to repair the powerblocks for the G150, G130, G180 and Micromaster 440 variable speed drives. Being a Siemens partner requires regular training on their product range. Our experts have therefore undergone training within Siemens in Germany to obtain this accreditation. Training in England: GMC G120 and S120 Quality is the watchword of a “Solution Partner”. Our experts have therefore been trained in the repair of the GMC G120 and S120 ranges in the United Kingdom. This accreditation also enables us to increase our responsiveness via access to all spare parts and components in this range.

Results

- Zero breakdowns linked to sectional elements - Productivity gains: No disruption to production

ST MICROELECTRONICS

Need / Context

STMicroelectronics wants to optimise the maintenance of its equipment at varying speeds. To achieve this goal, the company has entrusted us with the maintenance contract for its variable speed drives to minimise production stoppages... STMicroelectronics is a global leader in the development and production of silicon electronic components for a large number of applications, such as iPhone processors. The thickness of the fragile semiconductor layers is little more than a fraction of a millimetre, and their production and cutting require extremely accurate installations and maximum uptime. An interrupted cycle represents the equivalent of 3 weeks of production - i.e., millions of euros in losses. To meet these technological and sensitivity challenges, STMicroelectronics wants to optimise the maintenance of its equipment at varying speeds at the French site in Crolles, near Chambéry. DV GROUP was awarded the contract following a call for tenders.

Solutions

Through this 3-year contract, we will minimise production outages and breakdowns of the plant’s variables speed drives comprising more than 1,000 Siemens, ABB and Leroy Somer parts. This results-oriented agreement involves reducing the repair intervention rate and minimising production stoppages. To this end, the contract is based on “systematic” maintenance services, such as a preventive maintenance plan, preparatory work, monthly standby duties and telephone support. The contract also provides for services on a “case-by-case” basis according to the needs of STMicroelectronics (on-site intervention within a maximum of 4 hours, workshop repair and supply of spare parts by our sourcing unit). Our aim is not only to maintain the production tool but also to improve it. During this partnership, we will offer STMicroelectronics a performance review service that entails a summary of information collected during interventions to determine and present a particular area for improvement, such as the reliability of installations, the prevention of drifting, etc. DV GROUP’s goals for the next three years are to maintain, anticipate and improve.

Results

- Reduction in the repair intervention rate - Establishing a climate of trust: frequent, ongoing discussions and support with a dedicated DV GROUP contact person.

Our other solutions

for Electronic Maintenance

Numerical control

HMI and PLC

Electronic Intervention

Robot

Axis Drives

AC/DC Variable Speed Drives