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
Safety, Health, Environmental TPM in Administration Quality Maintenance Early Management 5 S Education and Training Planned Maintenance Focussed Improvement Autonomous Maintenance
• Schedules maintenance tasks based on predicted and/or measured failure rates • Step 1 duration: 2 – 3 months • Resources – PM pillar committee REDUCE MAINTENANCE COST BY 20% ZERO EQUIPMENT FAILURES AND BREAKDOWNS ENSURE IMPROVE AVAILABILITY OF RELIABILITY AND SPARES ALL THE MAINTAINABILITY TIME BY 50%
Time Performance Natural Forced Deterioration 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
Roles of the Production Department Maintenance Activities to be Performed Preventing Measuring Rectifying Maintenance Classification Deterioration Deterioration Deterioration Correct operation Normal Operation Setup and adjustment Cleaning and Countermeasures of defects Oiling Routine Maintenance Tightening Routine inspection of conditions of use and Minor maintenance deterioration Periodic Maintenance Periodic inspection Early Detection of Breakdown Maintenance situation and speedy countermeasures Enhancement of material strength Corrective Maintenance Reduction of load (Reliability) Enhancement of accuracy Corrective Maintenance Development of (Maintainability) condition monitoring
Roles of Maintenance Department Maintenance Activities to be Performed Preventing Measuring Rectifying Maintenance Classification Deterioration Deterioration Deterioration Periodic inspection Periodic examination Periodic Maintenance Periodic shutdown Unscheduled Predictive Maintenance Trend control shutdown Sporadic repair Breakdown Maintenance Early Detection of situation and speedy countermeasures Enhancement of material strength Corrective Maintenance Reduction of load (Reliability) Enhancement of accuracy Development of Improvement of condition monitoring maintenance work Corrective Maintenance (Maintainability) Improvement of Enhancement of inspection work maintenance quality
I ) Activities to Enhance Equipment Availability Activities to lengthen equipment MTBF Activities to shorten equipment MTTR 2. Planned Maintenance 7-Step activities 1. Guidance & Support for Jishu Hozen 3. Corrective Maintenance activities 5. Study of Predictive Maintenance 4. Maintenance Planning activities Maintenance Work Planning II) Activities to efficiently conduct Maintenance information management Input Reduction Maintenance spare parts management Maintenance cost management maintenance Knowledge and skill development Output Improvement – Zero failures, defects and accidents
STEP 0 SUPPORT AND GUIDANCE OF JISHU HOZEN ACTIVITY (AM) EVALUATE EQUIPMENT FAILURE/BREAKDOWN STATUS AND ASSESS STEP 1 THE CURRENT SITUATION STEP 2 RESTORE DETERIORATION AND CORRECT WEAKNESSES BUILD AN INFORMATION MANAGEMENT SYSTEM – SET STEP 3 MAINTENANCE STANDARDS BUILD A PERIODIC MANAGEMENT SYSTEM – TAKE ACTION STEP 4 AGAINST EQUIPMENT WEAKNESSES BUILD A PREDICTIVE MAINTENANCE SYSTEM – MAKE CHECKING STEP 5 AND OVERHAULING MORE EFFICIENT STEP 6 EVALUATE THE PLANNED MAINTENANCE SYSTEM IMPLEMENT PREDICTIVE MAINTENANCE AND ROLL OUT TO OTHER STEP 7 EQUIPMENT
1 Collect data on all failures/breakdowns causing production losses and analyse 3 2 Create and Creation and 4 implementation of maintain an Documents: Select PM equipment evaluation equipment ledger Equipment logs & equipment standard and ranking + negative map breakdown sheets Check sheet Mean time Frequency Breakdown of equipment between failures & Intensity Occurrence current Rate (MTBF) status 5 6 Prepare a plan to Set goals for the Mean time carry out the team with planned Maintenance to repair activities to achieve maintenance Cost (MTTR) the target
• 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. Designed by Date Substation/line name Installation location Equipment name Date created Model Purchased from Drawing Purchased date Purchase price per (R1,000) Periodic maintenance/modifications and Amount per Main failure and repair Amount per improvements (R1, 000) (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
Plant Component / Negative Map MTBF / MTTR spare parts list Planned Breakdown Equipment maintenance occurrence list classification schedule Goals for Equipment Equipment reducing ranking sheet ledger breakdowns
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