Automotive Industry Cluster

East Cape

CLEANER PRODUCTION

CLUSTER

PLANNED MAINTENANCE TARGET

ZERO EQUIPMENT FAILUE

AND BREAKDO

WN

REDUCE MAINTENANCE COST

BY 20%

ENSURE AVAILABILI

TY OF SPARES ALL THE

TIME

IMPROVE RELIABILIT

Y AND MAINTAINABILITY BY

50%

Deterioration

Time

Performance

Natural Deterioration

Forced Deterioration

Limit Line

What would cause forced deterioration ?

Forced Deterioration

• Sources – Vibration – Wear – Dirt – Dust – Debris

•Countermeasures Tightening Lubrication Cleaning

Aim of Autonomous Maintenance is to move the forced deterioration line closer to the natural deterioration line.

Combination Of Breakdown Causes •Five requirements for zero breakdowns:

1. Maintain basic conditions

2. Maintain operating conditions

3. Restore deterioration 4. Correct design

weaknesses 5. Improve operating &

maintenance skills

Basic conditions neglected

Inadequate skills

Inherent design weakness

Deterioration unchecked

Operating standards not followed

7 Steps for PM

Types of Maintenance

• Breakdown Maintenance - Intentional, not unplanned

• Periodic Maintenance - Time-based or Inspection & Repair

• Predictive Maintenance - CBM, use of technology for assessing condition

• Corrective Maintenance - Recurrence prevention

Responsibility for Maintenance

Pilot Area

Negative Map

Planned Maintenance Implementation Plan

1 – Initial Cleaning 2 – Sources of contamination, Hard-to-reach area 3 – Standardize

4 –Inspection system 5 – Entire process inspection

6 – A.M. System 7 – A.M. Management

INCREASE TIMELIFE Improve MTBF SYSTEMATIC REPAIR FAILURE PREDICTION

PHASE 1 PHASE 2 PHASE 3 PHASE 4

1 –Equipement Audit (Current)

2 –Repair degradations and improve weakness

3 – Information system (Database)

4 – Preventive Maintenance System 5 -Predictive

Maintenance System

AU

TON

OM

OU

S

MA

INTE

NA

NC

E

MA

INTE

NA

NC

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6 -Evaluate &

Establish P

LAN

NE

D M

AIN

TEN

AN

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S

YSTE

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Benefits of PM

Implementation of Planned Maintenance

EVALUATE THE PLANNED MAINTENANCE SYSTEM

BUILD A PREDICTIVE MANITENANCE SYSTEM

BUILD A PERIODIC MANAGEMENT SYSTEM

BUILD AN INFORMATION MANAGEMENT SYSTEM

RESTORE DETERIORATION AND CORRECT WEAKNESS

EVALUATION OF EQUIPMENT FAILURE/BREAKDOWN STATUS AND UNDERSTAND SITUATION

SUPPORT AND GUIDANCE OF JISHU HOZEN ACTIVITY

STEP 7

STEP 6

STEP 5

STEP 4

STEP 3

STEP 2

STEP 1

Guidance and Support for Autonomous Maintenance

GUIDANCE AND SUPPORTFOR AUTONOMOUS

MAINTENANCE

Support for RedTag system

Red Tagremoval listand removal

plan

Countermeasuresfor generation

sources

Support foreliminating the 4evils (Dirt, Rust,

Heat and Vibration)

Maintaining visualcontrol and displayinglabels, types of oil etc.

Support for makingstandards of cleaning,

lubrication andinspecting. Education ofoverall and inspection

for leader.

Training to ImproveMaintenance related

technical ability

STEP 1

Step 2

Evaluate and Understand the Current Conditions Evaluate and Understand the

Current Conditions

Creation andmaintenance of

equipment ledger

Creation andimplementation of

equipment evaluationstandard and ranking

EquipmentMaintenance

Record

Select PMequipment

MTBF

Check sheetof equipment

currentstatus

Frequency& Intensity

Rate

Process CapabilitySheet

MTTR MaintenanceCost

Set goals for theteam with planned

maintenance

Example Criteria for Evaluating Equipment

To decide which equipment receives planned maintenance

Equipment Ledger Control

(Page 30 PM)

• 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 RecordAsset No.

Equipment name

Model

Designed by

Date created

Purchased from

Insta

llation location

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)

Parts History of Equipment

(Page 31 PM)

Parts Breakdown History Record

(Page 32 PM)

Equipment Clarity Classification

• 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.

Critical Ranking and Maintenance Method

(Page 33 PM) • Rank failures as major, intermediate, or minor depending on their effect on equipment.

Evaluation Chart for Ranking Equipment (Evaluation Table for Selecting Priority Equipment)

4 2

4 2 1

4 2 1

1

4 2 1

4 2 1

Safety (SM)

9 Risk of a failure causing injury

10 Risk of a failure causing pollution

5

5

5

Quality (Q)

7

8Cost (C)

Product fabrication process capability

Fabrication cost

Total repair cost

6

1

Frequency of failures 4 2 1

1Production

(PD)

Average level of operation 5 4 2

Impact of a failure on other equipment 5 4 2

2

3

4

5 Downtime for repairing failures 4 2

1 1

Availability of space machine or alternate machine, and the ease of switchover 4 2 1

Classification EvaluationEvaluation points

Equipment name

Breakdown Occurrence List

• Obtain data on failure numbers, frequencies and severities, MTBFs ,etc.

• MTTRs (mean time to repair), maintenance costs, etc.

Control No. Name

1 2 3 4 5 6 7 8 9 10 11 12

Machine Failure Frequency Check-up Table

Month

Activity Plan to Eliminate Breakdowns

Set goals for reducing these through planned maintenance

Examples of planned maintenance goals

THANK YOU