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INDUSTRIAL CONSERVATION AND ITS RELATION WITH ECOLOGY. 1 TO EDUCATORS AND INDUSTRIALISTS OF THE WORLD INDUSTRIAL CONSERVATION AND ITS RELATION TO ECOLOGY. Ing. Enrique Dounce Villanueva. October 2011

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Page 1: industrial conservation ecology

INDUSTRIAL CONSERVATION AND ITS RELATION WITH ECOLOGY.

1

TO

EDUCATORS AND INDUSTRIALISTS OF THE WORLD

INDUSTRIAL CONSERVATION AND ITS RELATION TO ECOLOGY.

Ing. Enrique Dounce Villanueva.

October 2011

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Subjects to cover.

I. Objective

II. Thinking about the concept of Maintenance.

III. Industrial Conservation.

IV. An ecosystem’s sustainability.

V. Ecology and Industrial Conservation.

V. Mexico’s manufacturing system.

VI. Manufactured product or satisfactor.

VII. Industrial Effectiveness.

VIII. Manufacturing system’s ecology.

IX. Eco technology and Industrial Conservation.

X. Manufacturing systems’ conservation.

XI. Corollary.

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Objective:

To persuade educators and industrialists at world level that we must evolve

from the current concept of “Industrial Maintenance” to “Ecologic

Management of Systems”. It is urgent and necessary to take this step since

it will allow us to apply scientifically appropriate actions for the sustainability

of our habitat, which is a, and is immersed in, a cyclic system.

This will enhance our current knowledge, which will lead us to achieve a

world manufacturing industry ever more centered in its ecology.

Let us now explain the reasoning behind this objective.

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The knowledge about this topic was rudimentary and the tasks were performed

without sound scientific basis. The results we achieved were never the expected

goals, since “things did not get fixed”, costs increased and our users would

adamantly voice their complaints.

All of the above led us to research what “Industrial Maintenance” should actually be.

Thinking about the concept of “maintenance”

Since 1939, when I started my productive life in the Mexican Army at the

Transmissions Company, I performed “maintenance” tasks, which in those days it

meant “to fix things”.

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Thinking about the concept of “maintenance”

It was then that I first perceived that I had a mistaken concept regarding what

industrial “maintenance” and its scope was and that I shared this incorrect vision with

all of us working in this area.

After many years of working and collaborating with my professional team, we finally

understood that maintenance is a branch of Conservation.

Back in civil life, working for Telefonos de Mexico (Mexican Telephone Company)

as the person responsible for the “maintenance” of the phone plant, I had the

opportunity to go to the First International Symposium on Conservation, (1975)

which took place in Stockholm, Sweden. There, I found out that, unlike other

endeavors, the IMSS (Mexican Social Security Institute) did not have a

“Maintenance Department” but a “Conservation Department” which focused mainly

on caring for the habitat.

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Industrial Conservation.

It was then that our interest in studying about Conservation was born. To start our

studies, we looked among the Natural Sciences to search for a branch that would be

useful to understand the structure and functioning inherent to human life in its

environment. We chose Biology as our study source.

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In the figure below, we can see some of the branches of Biology. Since we

want to gain in depth knowledge about live beings and their habitat, know

about their origin, evolution, behavior, interrelations, etcetera, we found

that our best source for this objective is to study Ecology.

Industrial Conservation.

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This next image shows some of the branches of Ecology. Since our study

is focused on industry, we want to take a path that will allow us to

continue our analysis centering on industrial ecology.

Industrial Conservation.

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The figure below shows some of the branches of industry. Since our

essay is directed to solve the ecologic problems caused by

manufacturing industry’s operation, we will now proceed to present the criteria resulting from our analysis about ecology and industry.

Industrial Conservation.

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Industrial Ecology is a concept developed by industrial models’ scholars to

compare the Biological System with a Industrial System.

This concept seeks to reach an equilibrium between human activity and

that of Nature, developing processes that will allow taking to sustainable

levels, human activities needed in the search for satisfactors or productive

systems. The above requires that we study them thoroughly so that we

may acquire sufficient knowledge about these topics that will allow us to

obtain their necessary sustainability.

Industrial Conservation.

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An ecosystem’s sustainability.

Sustainability actions in an ecosystem permit the species contained

within it to remain in equilibrium with the resources involved in this

symbiosis. It is essential to know the ecosystem’s structure in regard to

the matter that comprises it (animal, vegetable, and mineral) and the

service that matter provides so that we can apply to it the appropriate

sustainability activities.

An Eco System Sustainability

Eco System’s Structure

Knowledge of the quality of matter

that comprises the Eco System

Knowledge of the quality of the

service provided by the Eco System

Eco System’s Conservation

Preservation of the quality of the matter

of the Eco System

Maintenance of the quality of the

service provided by the Eco System

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Ecology and Industrial Conservation.

From our analysis up to this point, we can see that there is a close

relationship between Ecology and Industrial Conservation and that their

joint study will aid, in an important manner, the development of our

country’s manufacturing system.

Let us make a pause here in our ecologic progress to combine it with the

“General Theory of Systems”, another subject that makes it easier for us to understand what Industrial Conservation is.

The theory of systems is based on the solar system’s activity, which

functions in a cyclic manner, so that change is constant and repetitive for all

the elements that comprise it (matter, energy, life, and habitat) and which

we need to know in depth to be able to apply the necessary Sustainability tasks.

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General Theory of Systems (GTS)

System.- It is a set of matter structured of elements or parts, located within

an environment, that are orderly related among themselves while

functioning, thus contributing to reach a specific goal. Any change or variation in any of these elements will cause changes in the whole system.

Systems in general

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It is a system which accomplishes symbiosis with the environment around it

and takes from its environment through its access, the inputs it needs (matter

and/or energy).

The open system performs its process generating the service for which it

was created and expels the excess matter and/or energy through its exit,

giving it back to its environment, which is necessary for the survival of other

systems of which their environments are involved.

Environment

Environment

Process Entry Exit

Open System

GTS- Open System.

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Environment

bbb bbb bbb bbb TEMP HYGR VAC AMP

Environment

Closed System

GTS – Closed System.

It is hermetic to any environmental influence. A closed system cannot

interchange matter with its environment, but it can exchange energy.

Its function is to continually evaluate the Open System and inform about

the degree of disorder which it has, thus allowing to apply the actions

required to restore its equilibrium.

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Process Entry Exit

Complete Systems

Environment

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Environment

The union of an Open System with its necessary closed system is considered a

Complete System since it can function indefinitely due to the information

provided by its Closed Systems about the system’s entropy, thus using the

needed internal forces to allow the survival of the Complete System.

GTS – Complete System.

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GTS – System of Systems.

A system of systems is what we usually find in a manufacturing company

as its manufactured product or satisfactor. As an example, let us think

of an automotive company for which, all the systems that comprise a car

are represented in the figure below, - there are thousands of interrelated

complete systems, all immersed in the same environment as the product,

(Car).

Environment

Entry Exit

Environment

Environment

Process Entry Exit From other systems To other systems

Environment

Environment

Process Entry Exit From other systems To other systems

Environment

Environment

Process Entry Exit Fromf other systems To other systems

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Ambiente

Ambiente

ProcesoEntrada SalidaDe otros

sistemas

A otros

sistemas

Ambiente

Ambiente

ProcesoEntrada SalidaDe otros

sistemas

A otros

sistemas

Ambiente

Ambiente

ProcesoEntrada SalidaDe otros

sistemas

A otros

sistemas

Environment

Environment

Manufactured Product or Satisfactor.

Here we have the final product of our automotive company. As

can be seen, with this product we want to provide satisfaction to

our possible clients that comprise a specific market formed by

their wishes.

We can achieve the above by ensuring that our product, when

operating, provides its user satisfaction during all of its

average promised life cycle.

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The survival of a manufacturing company depends on its effectiveness

which can be detected through its users acceptance expressed by their

favorable opinion regarding the satisfaction they derive from the use of the

company’s products, also called satisfactors.

The Satisfactor is the foundation we must always keep in mind and we

must base on it the solution to conservation problems. If our manufactured

Satisfactor is operating right, the manufacturing company is functioning

well.

Industrial Effectiveness.

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A product is formed by several material parts rationally structured to achieve a

predetermined objective.

Let us imagine a light bulb manufacturing company designing a product,

comprised by materials such as tungsten, glass, copper, sealing adhesive,

etcetera. Each of these elements has its own characteristics, and the whole is

structured to achieve a specific objective, which, in this case, is to provide

illumination with a quality defined by the market targeted.

Interrelated Matter

Product’s Analysis

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Let us now imagine approximately what happens when a light bulb is connected to

an electrical outlet:

An intense electrical current goes through a filament which causes it to become

incandescent, giving off light. To avoid the burning of the filament, the set of these

materials is placed into a high vacuum glass bulb.

We can now see clearly that the product has become a system. An energy

movement is immediately produced within it, going from electronic to thermal and

then to luminous energy, among others.

Internal operation of the product

1.Glass bulb .

2.High vacuum.

3.Support wires for filament.

4.Conductor wires.

5.Metal fitting.

1

2 3

4

4

5

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The light bulb, as a unit, is the product manufactured by the company,

which, in turn, guarantees that the light bulb will work as an Illuminating

System.

The light bulb remains idle and at the disposition of the final user until the

time it is required to provide illuminating service. From this moment

onward, the product becomes a system, that is, it becomes a Satisfactor.

Product and System

Product in operation = System = Satisfactor

Idle Product Functioning System = Satisfactor

Working product Service obtained

Lightning

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AN INDUSTRY IS EFFECTIVE WHEN A SATISFACTOR IS BALANCED

Satisfactor

Matter Service

Industrial Effectiveness

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Industrial Effectiveness - System’s Attributes

There are two opposing forces in industrial systems, Action and Reaction.

Let us analyze each of them.

The Action.

It is comprised by the following forces:

•Entropy. It is the tendency of systems to destroy themselves by consuming

more energy than they need.

•Defects. It is the tendency of the system to destroy itself caused by the

different matters that comprise it by being structured in series, in parallel, or in

series-parallel.

•Errors. Is the tendency of the system to destroy itself, involuntarily caused

by humans during the system’s operation or conservation.

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The Reaction.

It is comprised by the following forces:

•Homeostasis

It is la tendency of systems to maintain the basic characteristics with which

they were designed.

•Feed - Back

Feed-Back is the set of reactions within a system caused by a self-serving

mechanism or by humans to accomplish that the system remain in

equilibrium.

This attributes interact according to Newton laws during the time the

system is operating.

Industrial Effectiveness – System’s Attributes

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To each action there is a corresponding opposing equal reaction to the cause

producing it. If, throughout time the forces are equal, the system remains in

equilibrium.

Industrial Effectiveness – Forces interacting in the System

If, throughout time, the forces are different, the system will cease to exist.

Errors

Defects

Entropy

Homeostasis

Feed-back

Homeostasis

Feed-back

Errors

Defects

Entropy

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Let us keep following with our light bulb example, which has been designed

to provide an optimal luminous quality if an electric current of 120 Volts is

applied to it. It will provide an acceptable luminous quality if the electrical

current applied varies between 110 and 130 VAC. These are the

parameters for our light bulb when it is working as a system.

Industrial Effectiveness – Forces within the illumination system

As time goes by, the materials become degraded, errors occur randomly and

with variable acuteness, or feedback is not applied with the appropriate

opportunity and quality, so the system ceases to exist

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Industrial Effectiveness – System’s parameters

Using a control graph, let us now apply the criteria we have already seen to an AC

generator. With this generator we are committed to our user to deliver 120 VAC as

an optimum, with a 110 VAC as a minimum variance and 130 VAC as a maximum

variance. These parameters are shown in the control graph which includes three

areas, the control area, which includes the acceptable measurements, and the

failure areas, which indicate the measurement values that are not acceptable, that

is, the death of the system. The ideal is to take the system, through sustainability, to

operate on the equilibrium of forces line, until the end of the generator’s useful life

cycle.

Control

Areal

Failure area

Failure area

Time

130 Vac

120 Vac

110 Vac

Equilibrium of forces line

Action = Reaction

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Let us suppose that at the beginning the system worked well but as time goes by, due

to the difference between Action and Reaction, it reaches a point (1) where slowly

and imperceptibly, the system starts changing its temperature, pressure, wattage,

etcetera, until there comes a time when we perceive the changes, announcing a

“Potential Failure” (point 2). At this moment, we start to do the necessary research to

know the reasons for the deviation, plan its solution, and act in order to return the

system to its equilibrium line, applying RCM criteria.

.

Industrial Effectiveness - Interaction of Action and Reaction

Control

Area

Failure area

Failure area

Time

130 VAC

120 VAC

110 VAC

1

2 a

a) Disequilibrium line Action vs. Reaction

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Industrial Effectiveness - Example

Let us suppose that you are the operator of the generator we have been describing.

At the start of the shift, you do the usual checks in the generator to take it to the

appropriate parameters so that by 8 o’clock in the morning, the machine was already

working as a system. By 10:45, the voltmeter read as 125 volts, so you decided to

decrease the system’s velocity, and it returned to its equilibrium line.

Similar situations happened at 12:50 and 13:50 hours, when you attended properly

the problems. At 14:45 you had to go far from the machine, and at 14:55 hours you

were informed about the system’s failure. Costly emergency tasks had to be

performed, with the ensuing users annoyance. Imagine a problem like this one

happening in the Bullet Train or an Airplane.

Control

Area

Failure area

Failure area

Time

130 VAC

120 VAC

110 VAC

1

2

1

2

1

2

1

2

10:45 hrs.

12:50 hrs.

13:50 hrs.

14:55 hrs.

16:00 hrs.

Failure of death of system

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In reference to the importance of systems, these are classified as:

•Vitals these are the systems that when they close down or their operation is

degraded, they can cause loss of human life or catastrophic damages.

•Important these are the systems that when they close down or their operation is

degraded, they result in considerable costs.

•Trivial these are systems that when they close down or their operation is degraded,

the situation is not important.

Industrial Effectiveness - Vital Systems

In order to avoid failures in vital or important systems, since the XIX century, man

started to develop systems capable of auto-regulation, called self-serving

mechanisms. This type of mechanism when installed within a complete system’s

environment, capture the information provided by the closed systems and perform the

necessary modifications to restore the equilibrium between action and reaction of

the complete system.

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Self-Serving mechanisms. The figure below considers that the three subsystems are working at the same time,

but Number 1 is the one in charge of the Service. When an anomaly arises, it send

an “Out of Service” message to the exchange box, which will then obtain the Service

form subsystem 2. The process is repeated in a similar way if subsystem 2 fails,

getting the service from subsystem 3.

It is useful to see that every time one of the systems fails, the system’s Dependability

only decreases, thus providing time for its rehabilitation and perennial Reliability.

VITAL SERVICE

2 31

Subsystem1Outside of Quality

for service

Subsystem 2Outside of quality for

service

Subsystem 3Dentro de Quality for

service

a ba

Max.

OK

Min.

Time of operation

Qua

lity

of s

ervi

ce

x

Max.

OK

Min.

yMax.

OK

Min.

SELF-SERVICE MECHANISMSearching for the service withinThe expected quality

Time of operation Time of operation

Qua

lity

of s

ervi

ce

Qua

lity

of s

ervi

ce

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Feed-Back is the set of actions and reactions that are within a system, are caused

by their characteristic adversary forces, and are governed by self-serve mechanisms

or by man to attain the goal that the system remain in equilibrium during its useful

life time.

System’s Feed-Back

System with Self-serving mechanisms and human beings

Environment

Environment

Process Entry Exit

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SERVICIO VITAL

2 31

Sub-sistema 1

Fuera de calidad de servicio

Sub-sistema 2

Fuera de calidad de servicio

Sub-sistema 3

Dentro de calidad de servicio

a ba

Max.

OKMin.

Tiempo de operación

Calid

ad d

e s

erv

icio

x

Max.

OKMin.

Tiempo de operación

Calid

ad d

e s

erv

icio

y Max.

OKMin.

Tiempo de operación

Calid

ad d

e s

erv

icio

SERVOMECANISMO.Buscando el servicio dentro de la calidad estipulada.

SERVICIO VITAL

2 31

Sub-sistema 1

Fuera de calidad de servicio

Sub-sistema 2

Fuera de calidad de servicio

Sub-sistema 3

Dentro de calidad de servicio

a ba

Max.

OKMin.

Tiempo de operación

Calid

ad d

e s

erv

icio

x

Max.

OKMin.

Tiempo de operación

Calid

ad d

e s

erv

icio

y Max.

OKMin.

Tiempo de operación

Calid

ad d

e s

erv

icio

SERVOMECANISMO.Buscando el servicio dentro de la calidad estipulada.

SERVICIO VITAL

2 31

Sub-sistema 1

Fuera de calidad de servicio

Sub-sistema 2

Fuera de calidad de servicio

Sub-sistema 3

Dentro de calidad de servicio

a ba

Max.

OKMin.

Tiempo de operación

Calid

ad d

e s

erv

icio

x

Max.

OKMin.

Tiempo de operación

Calid

ad d

e s

erv

icio

y Max.

OKMin.

Tiempo de operación

Calid

ad d

e s

erv

icio

SERVOMECANISMO.Buscando el servicio dentro de la calidad estipulada.

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The beginning of the Manufacturing System can be related to the birth and

development of micro-businesses (Prehistory, ten thousand years ago). The

people that created them in order to obtain their vital satisfactors (clothing, living

facilities, food, etc.) were always occupied in their process but they also needed to

attend the acquisition of inputs and the sale of their product.

The topic we have thus far analyzed is now a reality. Let us think about the world net

of telecommunications comprised by systems open, closed, self-serve

mechanisms, and persons governing the different forms of electric, radial, nuclear,

etcetera energy, needed to establish quality human communication in seconds. This

happened similarly in the Manufacturing System. Let us see its birth and

development.

AN IMAGINARY EXAMPLE OF A MICRO-BUSINESS

The Manufacturing System

Suppliers Users

Inpunts Products

Process

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Due to sedentary life, the best micro-businesses started to join which gave rise

to the forming of small businesses. Their interrelation continued to obtain more

and better satisfactors, which became inputs and product that could be acquired

by both nomad and sedentary persons.

Manufacturing System.

Within this order of ideas, Micro businesses worked alone, for their own benefit and

others worked for Small businesses, and these among themselves, as well as with

clients and consumers, starting to form a net with its own life.

Micro 1

Micro 2

Micro 3

Micro 4

Suppliers Users

IMAGINARY EXAMPLE OF A SMALL BUSINESS

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MiSandMEs

Medium businesses were created in a similar way. We can now consider a

large net comprised of micros, Small and Medium businesses (MiSandMes)

integrated as complete systems with self-serve mechanisms, and persons

governing the actions and reactions of the whole.

The Industrial Firms

In developed countries, MiSandMEs provide over 99% of their Gross Internal

Product (GIP) and the rest is contributed by Big Businesses.

In Mexico, businesses are classified according to the number of employees,

and the economic sector to which they belong. For our purposes, we will use

the following classification:

Mi = Micro business from 1 to 10 employees

S = Small business from 11 to 100 employees

ME = Medium business from 101 to 250 employees

Big Businesses from 251 on

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From what we have seen so far, we can consider that any country can be

viewed as a true and living manufacturing net, comprised by its MiSandMes,

and including its Big Businesses.

No business within the system can live without an appropriate symbiosis to

the nearest environment in which it is immersed.

Viewed thus, the country also behaves as a system which imports its inputs

and exports its products, looking for progress.

Imports

(Inputs)

Exports

(Products)

Manufacturing System.

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Summarizing

To seek a better understanding, let us see the road we have followed during

this presentation:

Let us now continue with the development of Eco technology.

We started studying Ecology and proved that there is a close relationship

between Ecology and Industrial Conservation. We then moved to the

General Theory of Systems, learning their structure and operation until we

obtained the knowledge sufficient to understand the more developed systems,

integrated by self serve mechanisms and human beings. We later continued

with the creation and development of Manufacturing Systems which represent

a country’s dynamism. We also noted the importance of the country’s MiSandMes in the generation of the Gross Internal Product, (GIP).

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Eco technology.

Eco technology is composed of techniques developed to care for earth’s

habitat. Its goal is an efficient and efficacious use of energy and the

improvement of manufacturing processes.

Its application seeks the optimum and efficient use of energy and the

improvement of domestic, industrial and labor processes.

From Industrial Ecology’s point of view, Eco technology seeks to establish

industrial systems sustainable under two premises.

•Develop the input entries and product exits cycle.

•Promote energy’s efficiency through the use of energy in cascade

processes.

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Heat

Vapor

Carbon

Calcium Sulfate Waste water

Light Gas

Clay

Plaster waste

System’s Product Electriciy Centerl

Refinery

Pharmaceutical

Manufacturer

Community

Applied Ecotechnology.

Industrial Symbiotic environment

Inputs

Exit

(Products

and

Wastes)Pharmaceutical

Inputs

Manufacturing

Exit

(Products

and

wastes)

Comunidad

Inputs Exit

Inputs

Refinery

Exit

(Products

and

Wastes)

Electric Center

Exit

(Products

and

Wastes)

Inputs

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Manufacturing Industrial Ecology.

We have mentioned that an Ecosystem’s sustainability activities allow the species

contained within it to remain in equilibrium with the resources they are symbiotic with.

Let us remember our figure.

An Eco System’s

Sustainability

Eco System’s Structure

Knowledge of

Matter that integrates

Eco System

Knowledge of

Service provided

By Eco System

Eco System’s

Conservation

Preservatio of

quality of matter

of Eco System

Maintenance of

quality of services

provided by Eco System

We can conclude that we will achieve our country’s manufacturing system

sustainability, knowing in depth its structure and applying Conservation actions, and

not only maintenance.

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Industrial Conservation.

Industrial Conservation refers to every human action which, through the application of

scientific and technical knowledge, contributes to the optimal use of existing resources

in the human habitat, and promotes men and society’s integral development.

Industrial Conservation is applied to achieve sustainability for the ecologic system,

preserving the quality of matter and maintaining the quality of the service

provided by the matter.

Industrial Conservation

Preservation

(Quality of matter))

Maintenance

(Quality of service))

Industrial Conservation Branches

Let us apply these criteria to a manufactured product, for example a working light bulb,

a car, a train, etc.

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Let us remember that a working light bulb is an Illumination System and

that its sustainability will be obtained applying Conservation criteria, that

is, preserving the quality of matter and maintaining the quality of the

service.

Manufactured Product’s Conservation.

INDUSTRIAL CONSERVATION

To preserve the quality of matter

To maintain the quality of the service

Branches of Industrial Conservation

Let us now analyze what preservation is.

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Preservation refers to the actions to avoid the degrading of an object

through applying preventive measures to the main deterioration elements.

Preserving.

Conservation for the Manufactured Product.

Example for Preservation activities:

• Lubrication.

• Paint.

• Cleaning.

• Substitution of elements.

• Water proofing.

• Etc.

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Maintenance refers to human activities to guarantee a Service within an expected

quality.

Maintaining.

Conservation for the Manufactured Product.

Control

area

Failure area

Failure area

time

P

F System’s failure or death

Examples for Maintenance activities:

Important and trivial items

•Programmed restoration for components.

• Programmed replacement for components.

• Search for failures in closed systems.

Vital items.

• Electronic monitoring.

• RCM application (potential failure “P”).

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Since mid 20th. Century, Maintenance and Management, especially at their

top levels, have experienced an outstanding interdependent evolution, such

that, the end of that Century saw the emergence of the concept of “Asset

Management”. The British norm PASS 55 is derived from the above

mentioned concept. Its main objective is optimum management of assets to

achieve expected and sustainable results, but based on the original

Maintenance focus, not in the current concept of Conservation….

COROLLARY

What is the next step?

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Throughout this document, we have studied in depth several factors

regarding the importance of an ecologic focus required for Industrial

Conservation tasks. We have proved that there is a close relationship

between Industrial Maintenance, Ecology, and Eco technology.

COROLLARY (continues)

The next step is to take advantage of this relationship for the development of

companies without damaging their environment and their ecologic milieu.

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COROLLARY (continues)

The symbiosis among companies is very important. It can help minimize the

damage to the environment, and the usage of waste material generated by

each System generates, so that the systems can better use energy and

matter to create satisfactors.

This is the change in focus we require. This is the path to evolution we must

take:

FROM INDUSTRIAL MAINTENANCE

TO

ECOLOGIC MANAGEMENT OF SYSTEMS .