Total Productive Maintenance Planned Maintenance Step 1 Evaluate - - PowerPoint PPT Presentation

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 Management Education and Training

Autonomous Maintenance Focussed Improvement

Planned Maintenance TPM in Administration

Safety, Health, Environmental

Quality Maintenance 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

Time Performance Natural Deterioration Forced Deterioration Limit Line

• 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 Classification Preventing Deterioration Measuring Deterioration Rectifying Deterioration Routine Maintenance Periodic inspection Periodic 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 Classification Preventing 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 control Unscheduled shutdown Predictive 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 Department

Maintenance 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) Activities to efficiently conduct maintenance Input Reduction

Maintenance Work Planning Maintenance information management Maintenance spare parts management Maintenance cost management Knowledge and skill development

• 5. Study of Predictive Maintenance
• 3. Corrective Maintenance activities
• 4. Maintenance Planning activities
• 2. Planned Maintenance 7-Step activities
• 1. Guidance & Support for Jishu Hozen

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

• f 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 Installation location Purchased date Purchase price per (R1,000) Drawing Substation/line name Date 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)

To decide which equipment receives planned maintenance

• 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.

Examples of planned maintenance goals

Negative Map Equipment classification Equipment ledger MTBF / MTTR Breakdown

• ccurrence list

Planned maintenance schedule Goals for reducing breakdowns Component / spare parts list Equipment ranking sheet Plant