Read more in issue 206 of Cultivar Máquinas.North-American aeronautical engineer Joe Sutter summarizes maintenance choices very well: “That's what maintenance is: when it's going well, no one remembers it exists. When something goes wrong, they say it doesn't exist. When it's to be spent, they think it doesn't need to exist. But when it really doesn’t exist, everyone agrees that it should exist.” I constantly witness this reality in my daily life and this brilliant quote from Engineer Joe always comes to mind.
Agricultural machines (like airplanes) are not disposable to be used for a short period and then discarded – perhaps in the future. Therefore, they require maintenance to continue performing the services for which they were built. And the choice of maintenance starts when you purchase the machine.
I am frequently approached with questions: “Which brand or model requires the least maintenance or workshop?”, “Which one has the lowest maintenance cost?”, “Which one is easiest to maintain?” or, even, “Which machines do mechanics know best?”. And now? With calm and patience it is possible to clarify these questions. Of course, time and mastery of technical information are necessary to adapt the reality of each case and, above all, not to be contaminated by the influence of advertising. It is also common sense to avoid emotional opinions, as we have our preferences, and what's more, we carry our inevitable idiosyncrasies that are part of each person's existence. Ruminating on all these nuances, it is possible to provide some guidance. So, we dare.
All machines are built for a specific job. This is the beginning of every choice: identifying the service to be done. There is no machine to do all the work, no matter how multifunctional it is. Just as there is no perfect machine – except in cinematographic plays. Adapting the machine to the needs of the services, or vice versa, is the basic premise, otherwise there is no maintenance that can survive. For the rural man, this means knowing very well what must be done by the machinery on his property, with full knowledge of the services that must be performed. This is not a difficult task, but some need to seek guidance from specialist technicians and obtain information. Here's the first step.
Before we start choosing the machine, it is important to identify trained and qualified people for operation and maintenance. We have had cases of machines stopping due to lack of operator, and also due to the unavailability of qualified people to carry out maintenance. In our reality, we experience a stark contrast between unemployed people looking for work and, at the same time, a lack of qualified personnel for certain services, including the operation and maintenance of agricultural machinery. There is no point in having machines with cutting-edge technologies if there are no prepared people. We highlight this topic, as it is a reality that we have already witnessed: the owner acquired two new harvesters, invested in training for three employees and only one was able to operate the equipment. How horrible! The machine is ready, the harvest is waiting and there is no one left to put the equipment into production.
Service to be done, qualified personnel, now what? Choice of machine. Brand, model, technological resources... And maintenance? Not always remembered that it exists. But when it doesn't exist, then call the engineer. It is not enough to have an excellent machine, with all the resources that technology offers, and not have a good after-sales service, which includes maintenance, parts and trained people. The choice, therefore, must take into account this fundamental aspect: after-sales. And this has to be researched locally and within the reality in the vicinity of the property. Check if there is an accredited workshop with parts in stock and personnel prepared to carry out the services. It is also important to check the availability of independent workshops that are already prepared for maintenance services. These workshops often have structures superior to those of authorized resellers, and there are cases of resellers that outsource to such workshops. Therefore, it is an option to consider, but a very accurate and on-site verification is necessary.
Example of real situations in Rio Grande do Sul: in the south of the state there is a strong presence of a certain brand of agricultural machinery that provides excellent after-sales services, however in the central region of the state it is another reality, as the same brand leaves to be desired in this regard, while another has a strong presence next to rural properties. A similar incident also occurs between the regions of Missões and the western border of the State, but involving other brands of machinery. We can categorically state that in Rio Grande do Sul alone there are at least four different and very notable situations in after-sales and technical assistance services, both in the authorized network and in the services of independent workshops.
More than ever, it is necessary to know the reality of each location, that is, to have your feet firmly on the ground. Know what is really needed. In rural parlance: “Put your foot in the door and don’t let up”, as sales marketing is increasingly aggressive and petulant, if the producer is not prepared, they will find themselves in a leaky canoe. Of course, the country man is quite cool, but you have to be careful. Pampa’s meekness points us to caution in our choices.
Now it’s the property’s turn to prepare to receive the chosen machine. A new machine requires a suitable location, ideally it should also be a new warehouse, with new tools, new benches, etc. That’s too much to ask: “spend? It doesn’t need to exist.” Okay, so warehouse remodeled, clean, with cement floors, and closed. Yes, it can protect the equipment from the elements, especially winter and the high humidity in the South. I remember something I witnessed: an owner purchased a harvester in the middle of the summer harvest and used it little. Then he got involved with storage and sales and the machine was moved to an old, open warehouse, with only a roof and two closed sides. He spent the winter in such conditions. When it was necessary to put it into operation, the problem appeared. New machine equipped with electronic technology suffered interference from humidity in the connectors and cabling (even though they were shielded) and more in the fuel system, as the thermal variation associated with humidity in the air penetrates the devices, and it was not possible to make it work. Call technical assistance. Services, contaminated parts, cleaning and decontamination, some replaced, diagnostic tests, displacement of maintenance teams. The owner’s words: “It cost R$ 20 thousand”. He learned his lesson hard. End of harvest: general preventive on the machine and store it in a suitable place. And one more very important item, which is often forgotten: putting the equipment to work at least once a month. Operate and move with the activation of all available resources and controls. At least for a period of one hour – at the very least.
Finally, we highlight the aspects of qualification and preparation of maintenance and operation teams. Current machines require different care and operational and maintenance practices among themselves and among older ones. Therefore, more than ever it is important to follow the recommendations set out in the manufacturers' manuals. These are new procedures and new workshop and operating routines that, compared to older machinery, require behavioral changes, and this is known to require a lot of caution and a lot of training and guidance. For many years we lived with a few machine models that were quite similar. A fact that has changed a lot recently. Often an operating procedure accepted on a particular machine is not recommended for another. So: lots of training and correct guidance, observing the procedures recommended by the manufacturers.
And there are also significant changes in workshop routines. In addition to traditional tooling, computers with special software, diagnostic equipment, electronic test benches, and specific tools for removing and installing components are required. A different look from that old dusty workshop with oil and grease dirt. Now, the environment has to be clean and contamination-free, otherwise the electronic components undergo changes and no longer function correctly, resulting in higher costs. Services with oil and grease residues are still present, but require care and rapid removal for proper collection.
We are facing a new reality. I remember an old workshop belonging to a childhood friend, where at the entrance he posted a notice with the following words: “The difficult thing is already ready; the impossible takes a while; and we do miracles too.” This time of miracles has passed, now there is a lot of knowledge, information and work connected to technical manuals and support networks. To this end, trained and qualified people. That mechanic covered in grease and with dirty overalls is part of the past, today it is the mechatronics or multifunctional teams around the machine. Services are faster, as long as they are carried out as recommended and with appropriate tools.
What about rural producers, who previously had some operators who also performed the main maintenance services, what do they do now? Maintenance is essential. So, how to do it? Each administrator has their own criteria for choosing maintenance, the important thing is that they recognize that it exists and that it is necessary for the good performance of the machinery. It can all be outsourced, which is a trend at the moment. There are those who opt for maintenance with their own team, as they maintain more efficient control of services, perhaps at a slightly higher cost than outsourcing. There is a mixed option, that is, it maintains a reduced maintenance team, more focused on basic preventive, and uses outsourced services for major revisions or possible corrective and emergency maintenance. Some administrators are adopting a different regime, where one or two employees take over the operation and basic preventive maintenance of the machine, that is, they are machine managers. They are responsible for keeping the machine in full working order. Of course, this requires a complete set of tooling support, an appropriate location and a stock of parts and fluids for replacements during preventive maintenance, to speed up the execution of services. It is important to highlight this aspect of the stock, as otherwise there will be machine and employee downtime waiting for the material to arrive. I highlight this situation because I have already witnessed it. I am very sympathetic to this system of machine managers, but qualified people are essential in every sense: technical-operational, knowledge of maintenance and safety, and above all, knowing how to work as a team and have correct professional ethical behavior, as it requires more responsibility. I confess that professional ethics, in the current situation, is something scarce, but it is still possible to find it.
Joel S. Alves,
Operation and Maintenance Instructor of Agricultural and Road Machinery and Implements
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