total productive maintenance - · pdf filesupport and guidance of jishu hozen activity (am)...
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Total Productive Maintenance Planned Maintenance
Step 1 Evaluate equipment failures
and assess the current situation
• PLANNED MAINTENANCE OBJECTIVE
• EQUIPMENT DETERIORATION
• TYPES OF MAINTENANCE
• PM RESPONSIBILITIES
• ROLE OF PRODUCTION
• ROLE OF MAINTENANCE
• PLANNED MAINTENANCE ACTIVITIES – STEP 1
• DOCUMENTATION EXAMPLES
Early
Managem
ent
Educatio
n a
nd T
rain
ing
Auto
nom
ou
s M
ain
tenance
Focussed Im
pro
vem
ent
Pla
nned M
ain
tenance
TP
M in
Adm
inis
tratio
n
Safe
ty, Health
,
Enviro
nm
enta
l
Quality
Main
tenance
5 S
ZERO EQUIPMENT
FAILURES AND BREAKDOWNS
REDUCE MAINTENANCE
COST BY 20%
ENSURE AVAILABILITY OF SPARES ALL THE
TIME
IMPROVE RELIABILITY AND
MAINTAINABILITY BY 50%
• Schedules maintenance tasks based on predicted and/or measured failure rates • Step 1 duration: 2 – 3 months • Resources – PM pillar committee
• Breakdown Maintenance
- Intentional, not unplanned; repairing after breakdowns occur
• Periodic Maintenance
- Time-based Maintenance or Inspection & Repair
• Predictive Maintenance
- Condition Based Maintenance; use of technology for assessing
conditions
• Corrective Maintenance
- Recurrence prevention; improving or modifying equipment to
prevent breakdowns or make maintenance easier
Maintenance ClassificationPreventing
Deterioration
Measuring
Deterioration
Rectifying
Deterioration
Routine Maintenance
Periodic inspectionPeriodic Maintenance
Breakdown Maintenance
Corrective Maintenance
(Maintainability)
Corrective Maintenance
(Reliability)
Minor maintenance
Early Detection of
situation and speedy
countermeasures
Enhancement of
material strength
Reduction of load
Enhancement of
accuracy
Development of
condition monitoring
Oiling
Tightening
Cleaning and
Countermeasures of
defects
Routine inspection of
conditions of use and
deterioration
Roles of the Production Department
Normal Operation
Correct operation
Setup and adjustment
Maintenance Activities to be Performed
Maintenance ClassificationPreventing
Deterioration
Measuring
Deterioration
Rectifying
Deterioration
Sporadic repair
Improvement of
inspection work
Corrective Maintenance
(Maintainability)
Improvement of
maintenance work
Enhancement of
maintenance quality
Breakdown Maintenance
Development of
condition monitoring
Periodic examination
Periodic shutdown
Periodic Maintenance
Trend controlUnscheduled
shutdownPredictive Maintenance
Periodic inspection
Early Detection of
situation and speedy
countermeasures
Corrective Maintenance
(Reliability)
Enhancement of
material strength
Reduction of load
Enhancement of
accuracy
Roles of Maintenance DepartmentMaintenance Activities to be Performed
I ) Activities to Enhance Equipment Availability
Activities to lengthen equipment MTBF
Activities to shorten equipment MTTR
Output Improvement – Zero failures, defects and
accidents
II)
Activitie
s to e
ffic
iently c
onduct
main
tenance
Inp
ut
Re
du
ctio
n
Maintenance Work Planning
Maintenance information management
Maintenance spare parts management
Maintenance cost management
Knowledge and skill development
5. S
tudy o
f P
redic
tive M
ain
tenance
3. C
orr
ective M
ain
tenance a
ctivitie
s
4. M
ain
tenance P
lannin
g a
ctivitie
s
2. P
lanned M
ain
tenance 7
-Ste
p a
ctivitie
s
1. G
uid
ance &
Support
for
Jis
hu H
ozen
IMPLEMENT PREDICTIVE MAINTENANCE AND ROLL OUT TO OTHER EQUIPMENT
EVALUATE THE PLANNED MAINTENANCE SYSTEM
BUILD A PREDICTIVE MAINTENANCE SYSTEM – MAKE CHECKING AND OVERHAULING MORE EFFICIENT
BUILD A PERIODIC MANAGEMENT SYSTEM – TAKE ACTION AGAINST EQUIPMENT WEAKNESSES
BUILD AN INFORMATION MANAGEMENT SYSTEM – SET MAINTENANCE STANDARDS
RESTORE DETERIORATION AND CORRECT WEAKNESSES
EVALUATE EQUIPMENT FAILURE/BREAKDOWN STATUS AND ASSESS THE CURRENT SITUATION
SUPPORT AND GUIDANCE OF JISHU HOZEN ACTIVITY (AM)
STEP 7
STEP 6
STEP 5
STEP 4
STEP 3
STEP 2
STEP 1
STEP 0
Create and
maintain an
equipment ledger
+ negative map
Creation and
implementation of
equipment evaluation standard and ranking
Breakdown Occurrence
Select PM
equipment
Mean time
between failures
(MTBF)
Check sheet
of equipment
current
status
Frequency & Intensity
Rate
Maintenance
Cost
Set goals for the
team with planned
maintenance
Collect data on all
failures/breakdowns
causing production
losses and analyse
Documents:
Equipment logs &
breakdown sheets
Prepare a plan to
carry out the
activities to achieve
the target
1
2 3 4
5 Mean time
to repair
(MTTR)
6
• Equipment logs are raw data for evaluating equipment. Must have design data and show equipment’s operating and maintenance history.
• Collect all data on the failures/breakdowns, which caused production loss and analyse.
Equipment Management Record
Asset No.
Equipment name
Model
Designed by
Date created
Purchased from
Insta
llatio
n lo
catio
n
Purchased date
Purchase price per (R1,000)
Drawing
Substation/line nameDate
Periodic maintenance/modifications and
improvements
Amount per
(R1, 000)
Main failure and repair Amount per
(R1, 000)
Date Location Details (in-house manhour)Date Location Details (in-house manhour)
• Evaluate each piece of equipment in terms of its effect on safety, quality, operability, maintainability, etc. • Rank equipment (as A, B, or C, for example) and perform maintenance on all units ranked A or B, as well as those for which zero failure is a legal requirement.
• Obtain data on failure numbers, frequencies, MTBFs, etc.
• MTTRs (mean time to repair), maintenance costs, etc.
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