Machine Maintenance
Plant Maintenance
Plant Maintenance is the health care of plant. The way preventive medicine
has greatly improved health care for the human body; preventive
maintenance has done the same for manufacturing plants. Failures and
defects are the illness of equipment. To prevent such illness routine
maintenance (cleaning, oiling, tightening, and inspection) must be
implemented. All of us can and must protect the equipment we use
ourselves by regular checkups. This is called Autonomous Maintenance in
TPM terminology.
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Machine Maintenance
subsequent changes. TPM is now rapidly spreading through a wide range
of manufacturing industries, such as the steel making, mass manufacturing,
chemical, food stuffs, and cement industries. TPM, a unique Japanese
system of managerial expertise, was created in 1971, based on the PM
(Preventive maintenance OR Productive maintenance) concept introduced
from the United States in the year 1950.
Many production systems are human-machine systems. Dependence
of production systems on an equipment increases as automation
progresses. And hence the machine efficiency depends on the methods of
manufacturing, usage and maintenance.
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Machine Maintenance
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Machine Maintenance
The aim of TPM is to maximize the production efficiency by:
1. Preventing the occurrence of stoppage losses due to failures
2. Eliminating the speed losses resulting from minor stoppages
3. Eliminating the defect losses caused by process defects
4. Improving the method of manufacturing
Basic Principles of Quality Maintenance
5S
Problems cannot be clearly seen when the work place is unorganized.
Cleaning and organizing the workplace helps the team to uncover
problems. Making problems visible is the first step of improvement.
Japanese Term
English Translation
Seiri
Organisation
Sort
Seiton
Tidiness
Systematise
Seiso
Cleaning
Sweep
Seiketsu
Standardisation
Standardise
Shitsuke
Discipline
Self - Discipline
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Machine Maintenance
Maintenance Terms and Terminology
Availability
The percentage of time a machine is actually able to produce parts out
of the total time that it should be able to produce. This number includes
breakdowns, setups, and adjustments.
Basic condition
The expected good state of repair that equipment should possess in
order to produce quality parts in a timely manner. Under TPM, operators
are expected to maintain their machine's basic condition.
Breakdown maintenance
Maintenance performed on broken machines to restore them to working
order.
Continuous improvement
Replacing ineffective practices, machines or manufacturing processes
with effective ones; To achieve ongoing measurable gain. Organizations
must constantly measure the effectiveness of processes and strive to
meet more difficult objectives to satisfy customers.
Downtime
Downtime is the period of time when a machine or a factory is not
operating and is not producing.
Overall equipment effectiveness
OEE; The percentage of equipment's
performance multiplied together.
availability,
quality,
and
Performance rate
The rate parts are produced divided by the machine capacity. This
number includes the number of parts produced in a given time, reduced
speeds, idling, and short-term stoppage for jams and other problems.
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Machine Maintenance
Periodic maintenance
Maintenance performed on a calendar basis.
Planned maintenance
Maintenance that is performed purposely and regularly in order to
prevent a machine from deteriorating or breaking down.
Predictive maintenance
Maintenance performed based on the known and expected behavior,
condition, and history of the machine.
Preventive maintenance
Maintenance performed while a machine is still in working order to keep
it from breaking down. Preventive maintenance includes lubricating,
tightening, and replacing worn parts.
Mean Time Between Failures (MTBF)
MTBF is a basic measure of reliability for repairable items. It can be
described as the number of hours that pass before a component,
assembly, or system fails. It is a commonly-used variable in reliability
and maintainability analyses.
Mean Time To Failure (MTTF)
MTTF is a basic measure of reliability for non-repairable systems. It is
the mean time expected until the first failure of a piece of equipment.
MTTF is a statistical value and is meant to be the mean over a long
period of time and large number of units. For constant failure rate
systems, MTTF is the inverse of the failure rate.
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Machine Maintenance
Autonomous Maintenance
Maintenance that is performed by the person who runs the machine
rather than the maintenance staff is Autonomous Maintenance.
Autonomous maintenance includes tasks such as lubricating and
tightening machine parts. As most of the Lean Manufacturing techniques
and tools, autonomous maintenance is based on education and training.
It is about raising awareness of the person on the knowledge and
understanding the operation principles of their machines. We can
perform following activities to maintain the equipment in productive
condition.
Daily checks
Lubrication
Replacement of parts
Repairs
Precision checks
Early detection of abnormal conditions
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Machine Maintenance
Three Skills
To practice autonomous maintenance, we must learn three skills. These
skills enable us to predict and take necessary action to prevent failure
and improve efficiency of machine.
1. Ability to determine and judge if operating conditions become
abnormal
Ability to determine abnormality is one of the key skill we should
posses. Without understanding the operation condition and
abnormality, we cannot anticipate the behavior of machine and
hence will fail to foresee the future failures.
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Machine Maintenance
7 steps of Autonomous Maintenance
1. Clean the machine.
2. Take measures to tackle the causes and the results of dust, oil and
dirt.
3. Develop standards and procedures for cleaning and oiling.
4. Adequate training to be effective inspectors.
5. Set-up inspection lists that will enable production employees to
keep the machines in optimum condition.
6. Develop standards and procedures to organize the workfloor
(including safety, health, order and cleanness).
7. Implement a totally autonomous maintenance system.
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Machine Maintenance
Look at and touch every corner of equipment to enhance its
care and to promote curiosity and questions
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Machine Maintenance
Feel pleasure and satisfaction with successful achievement
of improvement
Manager Support
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Machine Maintenance
3. Cleaning and lubrication standards
Major Activities
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Machine Maintenance
4. Overall inspection
Major Activities
Learn structure, function and inspection methods of equipment to master inspection skill
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Machine Maintenance
5. Autonomous Maintenance standards
Major Activities
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Machine Maintenance
6. Organisation
Major activities
Teach quality specifications, quality causes and quality results along with their relationship
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Machine Maintenance
7. Autonomous maintenance
Major Activities
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Machine Maintenance
KAIZEN
"Kai" means change, and "Zen" means good (for the better). Basically
kaizen is for small improvements, but carried out on a continual basis
and involve all people in the organization. Kaizen is opposite to big
spectacular innovations. Kaizen requires no or little investment. The
principle behind is that "a very large number of small improvements are
more effective in an organizational environment than a few
improvements of large value. This pillar is aimed at reducing losses in
the workplace that affect our efficiencies. By using a detailed and
thorough procedure we eliminate losses in a systematic method using
various Kaizen tools. These activities are not limited to production
areas and can be implemented in administrative areas as well.
Kaizen Policy
1. Practice concepts of zero losses in every sphere of activity.
2. relentless pursuit to achieve cost reduction targets in all resources
3. Relentless pursuit
effectiveness.
to
improve
over
all
plant
equipment
Kaizen Target
Achieve and sustain zero loses with respect to minor stops,
measurement and adjustments, defects and unavoidable downtimes. It
also aims to achieve 30% manufacturing cost reduction.
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Machine Maintenance
Tools used in Kaizen
1. PM analysis
2. Why - Why analysis
3. Summary of losses
4. Kaizen register
5. Kaizen summary sheet.
The objective of TPM is maximization of equipment effectiveness. TPM
aims at maximization of machine utilization and not merely machine
availability maximization. As one of the pillars of TPM activities, Kaizen
pursues efficient equipment, operator and material and energy utilization
that is extremes of productivity and aims at achieving substantial effects.
Kaizen activities try to thoroughly eliminate 16 major losses.
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Machine Maintenance
Category
Management loss
Operating motion loss
Line organization loss
Logistic loss
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Machine Maintenance
13. Measurement and adjustment loss
14. Energy loss
15. Die, jig and tool breakage loss
16. Yield loss.
Classification of losses
Aspect
Sporadic Loss
Chronic Loss
Causation
Remedy
Easy to establish a
remedial measure
Impact / Loss
Frequency of
occurrence
The frequency of
occurrence is low and
occasional.
Corrective
action
Specialists in process
engineering, quality
assurance and
maintenance people are
required.
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