Virtual case comparison CTP maintenance work
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The equipment is sold to the customer, only the lowest-level contract type work is completed. The complete after-sales service chain is the guarantee for the profit and continuous operation of the customer. The machine must be maintenance and repair-proof, and it can bring efficiency for a long time. Below, I will compare machine maintenance work from the traditional mode and the information 4.0 mode through a virtual case.
Case: The equipment sales company sold a CTP platesetter to a customer far away in the frontier, completed the installation and the machine was working properly.
In the first year, the equipment sales company can provide a full year of equipment warranty work, and the equipment is brand new, including consumables, repairs, training, etc., without paying extra fees.
The service life of the laser head of the machine is about 5,000 hours, and the maintenance time of the air and vacuum filter is 1500-2500 hours. The service life is determined according to the customer's site conditions.
The laser head life of the machine is more than 5,000 hours. Because it is a laser product, it may have a direct impact on the life of the laser head according to the consumables used by the customer and the customer's environment.
Soil method: CTP maintenance in the traditional mode
Step 1: understanding the situation
The maintenance engineer looks at the maintenance manual or the installation record to understand the current situation of the customer equipment. Usually, the following forms form the maintenance record form.
Step 2: maintenance
The maintenance engineer goes to the location of the equipment to remove dust, refuel, and maintain the equipment. If necessary, apply to the service engineer to initiate the task of replacing the air filter, vacuum filter and replacement parts.
Step 3: repair
The service engineer replaces the air filter, the suction filter, and initializes the current data according to the service manual and records it in the maintenance form.
CTP vacuum filter
CTP air filter
Step 4: Replace or check some key parts and repeat the repair steps
Engineers may be involved in replacing or inspecting critical parts, such as the machine's laser head or motor drive components, when inspecting or replacing equipment consumables. If there are problems, you will follow the above steps.
As a result, the air filter or the suction filter was replaced successfully. However, it takes at least 3 days to complete the work. If there are other problems during the inspection, the equipment will be extended for a longer period of time. And the running cost is far greater than the cost of replacing the filter.
Ocean approach: CTP maintenance under Information 4.0 mode
Step 1: remote analysis
The intelligent remote diagnostic system records the air quality, workload, media data, air quality inside the machine, intelligent diagnosis of the laser head, automatic diagnosis of the circuit board and drive components from the date of installation of the air filter or dust filter. The internal temperature of the cabinet and other data are calculated and analyzed.
Step 2: intelligent pre-judgment
The intelligent remote diagnostic system extracts future weather and air quality conditions and analyzes the air filter or vacuum workload to obtain specific data. If the air continues to be heavily polluted in the future, or the internal environment air filter is not efficient. The maintenance cycle has been reset to a non-standard time, and the replacement cycle has been reset for the automatically calculated time.
Step 3: the intelligent system pushes the maintenance related information, and the engineer handles it in time.
The intelligent system pushes the air filter maintenance time, maintenance methods and other information directly to the equipment sales company duty engineer. The duty engineer will pass this information to the customer's site staff or nearby engineers. The operator or engineer who receives the information will check the status of the device and report it. The intelligent system periodically initiates the task of replacing the air filter and periodically checks the spare parts storage.
Step 4: Sales company for inventory planning
The sales company calculates and analyzes the internal temperature and air quality index of the cabinet of the CTP machine that the customer feedbacks. The sales company analyzes and calculates the service life of the air filter, related consumables and accessories. Make an improvement plan for inventory or parts.
Step 5: Sales company push parts replacement reminder
The sales company pushes the CTP machine air filter to clean the filter filter time to the customer and set a reminder. To facilitate access to relevant maintenance data.
Step 6: Delivery of accessories, remote guidance installation by engineers, recycling of used accessories
Before the filter replacement, the sales company will deliver the relevant consumables and accessories to the destination according to the time reminder, and the engineer will guide the installation in real time and remote video. If the customer can't complete the relevant work, the system will find the nearest familiar engineer, arrange the engineer to replace the relevant accessories at the first time, the sales company will give the old filter recycling point information of the CTP machine near the customer, and the recycling process will be green.
Result
——CTP air filter replacement is successful, and some data information will be transmitted to the manufacturer. It can automatically make correct analysis for the diagnostic data generated by the equipment every day, and extract the suspected points that have influence on the equipment to be sent to the customer equipment management department or service. The company's engineers have comprehensively repaired the equipment in a preventive manner.
——On the other hand, the manufacturer analyzes the customer's geographical analysis of the number of consumables and different quality requirements that the customer needs to provide further production processing. Accurate maintenance of equipment, covering basic cleaning, cleaning, replacement and other actions. Although replacing the air filter is a very simple maintenance work, and the participation is completely completed under the information, human intervention is rare, and people have more time or Focus on the completeness of the equipment.