Preventive / Autonomous Maintenance - Beginners guide

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This presentation explains preventive and Autonomous Maintenance techniques in a simple manner with numerous "Before & After" pictures.
There are also formats available at the end of the presentation on the MIS reports and analysis to be done in the Maintenance function.
Please visit www.businessense.in to download this document.

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Preventive / Autonomous Maintenance - Beginners guide

  1. 1. MAINTENANCEMODULEAn initiative of Hash Management Services LLPA Business Sense PublicationFor more free resources visit www.businessense.in
  2. 2. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Overview ‘The Essentials’ series from Business Sense is an initiative to empower the professionals and students in performing moreefficiently and effectively in the organization This publication is aimed at bridging the gap between the institutions and the industry by providing the fundamentals ofmanufacturing management which are not offered by any of our institutions/curriculum This course would immensely benefit professionals and students who are joining manufacturing organizations At Business Sense, we help medium scale manufacturing units improve their operational efficiency through consultingengagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED,Kaizen and other tools We promise to double the productivity in less than 33 days of our effort In addition, our web application would help the senior management in monitoring the important business updates every dayand provide them analytics and enable them better decision making. Useful if your organization do not have an ERP For more details, please visit www.businessense.in You can subscribe to our bi-weekly newsletter here. Follow us:
  3. 3. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Introduction to Maintenance Function Maintenance function ensures that all the machines and equipments related to theproduction and other key functions in the organization are maintained and function properly Maintenance Function plans for the spares and consumables for the maintenance They co-ordinate with outside agencies / other functions in case of layout change / wiring /machine movement, etc Maintenance should ensure that there should not be any breakdowns of any machines
  4. 4. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Introduction to Maintenance functionFollowing are the critical job responsibilities of Maintenance Function To bring the Machine to Basic condition Taking Machines to Higher Levels of Performance To Move towards Zero Failures , Zero Defects & Zero Accidents There are 2 basic types of maintenance Break-down Maintenance – Done after the Machine breaks down Preventive Maintenance – before the Machine breaks down - done by theMaintenance team at regular intervals to keep the machine in workingcondition Autonomous Maintenance (AM) is a part of Preventive Maintenance (PM) AM is done by the operator themselves on a daily basis Over a period of time, Break-downs of machines should become zero!MaintenancePreventiveMaintenanceAutonomousBreakdownMaintenance
  5. 5. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Break-down Maintenance Once a particular machine breaks down, the operator informs theproduction supervisor to raise a complaint to the Maintenance team Maintenance team rushes to the machine and fix the issue Most companies have a Service Level Agreement with the Maintenance teamto attend the machines ( e.g. maintenance team personnel should reach themachine with in 30 min )
  6. 6. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Preventive Maintenance This is a schedule based maintenance program which would be done bythe maintenance team Daily / weekly / fortnightly / monthly / quarterly plan for all machines A preventive Maintenance calendar should be created covering all majormachines in the company and person responsible for the same
  7. 7. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Autonomous Maintenance (AM) Would be done by the operator themselves Cleaning / Lubrication / Re-tightening / Inspection are covered underAutonomous Maintenance Minor spare change can also be covered under AM
  8. 8. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Steps for Implementing AM1. Preparation2. Cleaning and Inspection3. Eliminate Problem Sources and abnormalities4. Cleaning, Lubrication, Re-tightening, Inspection – Checklists and Audits5. Visual ManagementPlease note that this list covers only the basics. This is not the exhaustive list of steps as prescribed by the TPM model
  9. 9. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Step 1 – PreparationStep 2 – Initial Cleaning & Inspection
  10. 10. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Step 1- Preparation Identify the Machine parts and the purpose /activity of the part in the machine Know the function of the machine Know the safety aspect of the machine Operator Training to handle the machineKnowing the machine & itsparts is the primary step
  11. 11. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Step 2- Cleaning and Inspection Initial Cleaning of the Machine Identification of Abnormality Hard to Access area Source of Contamination & Localization Unsafe Conditions
  12. 12. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Initial Cleaning of the Machine Before cleaning, all WIP materials in the machine to beproperly covered. Cleaning Agent should not be used on the Machine partswhere there is direct contact with the materials Cleaning tools: Cotton Waste Tool Box / Trolley Wire Brushes Ladder , Screw Driver Emery Sheet - Medium Cleaning Agent – Kerosene , Soap oilThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  13. 13. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Identification of Abnormality Dust Dirt Leak Rust Loose Damage Deformed Bolts and nuts/ joints Lubrication Transmission Hydraulics Pneumatics – gas system Electrical Safety Non standard Vibration Noise Misalignment Shaking Worn out MissingAbnormalities Where to find them?
  14. 14. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Step 3 – Elimination of abnormalities
  15. 15. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormalities in Bolts and Nuts Missing Loose Shaking Non standard bolts / washers Rusted Corroded Damaged Excess / low length Paint on threads and head
  16. 16. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality - Missing NutMissing Nut Nut fixedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  17. 17. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality - Missing screwMissing Screw Screw fixedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  18. 18. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – different nutDifferent Nuts Same type nutsThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  19. 19. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – Painted boltBolt head painted!Difficult to remove the bolt in futurePaint removed from the bolt headThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  20. 20. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – bend in the boltBend in the bolt New bolt and nut fixedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  21. 21. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – different size washersDifferent washers used Washers fixedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  22. 22. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – rust in the bolt threadRust in the bolt thread Rust removedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  23. 23. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormalities in lubrication Lubrication System Not Working No Grease in Reservoir No Visibility No Oil in the Gear Box Lubrication Level Low /High Grease / oil - Leak Without Grease Nipple & Cap Reservoir Tank Open Excess Greasing Oil / Grease Dust ContaminationThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  24. 24. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – No grease in the reservoirNo grease Grease filledThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  25. 25. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – grease level not visibleGrease level not visible Grease level visibleThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  26. 26. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – excess greaseExcess grease Optimal greaseThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  27. 27. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormalities in Transmission Slackness Tight Damaged Misalignment Noise Key way worn out Key shaking Pulley/ belt / gear / shaftdamaged Belt missing Tracking Eccentricity Play
  28. 28. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality - slacknessSlackness in belt Slackness removedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  29. 29. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – cooling fan not availableCooling fan – not available Cooling fan fixedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  30. 30. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – chain guard not availableChain guard – not available Chain Guard - fixedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  31. 31. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – oil leakageOil Leakage from the machine Oil Leak fixedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  32. 32. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormalities in Hydraulic System Oil level low / high Oil contaminated Tank open Oil pressure low / high Oil temperature high Jerks / vibration Line damage Line not routed properly Noisy pump Pressure gauge not working Oil leak
  33. 33. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – gauge not workingGauge damaged / not working Gauge repairedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  34. 34. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormalities in Pneumatic System Air / gas leak Line damage Line not routed properly Sluggish cylinder movements FRL unit not fixed in order Filter not drained of moisture Lubricator level low / high Oil flow rate high
  35. 35. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – air leakageAir leakage Leakage arrestedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  36. 36. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – Steam leakageSteam leakage Steam Leakage arrestedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  37. 37. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormalities in Electrical System Loose connections Hanging wires Cable not routed properly Cable gland loose Motor generating noise Motor generating moreheat Exposed wires Panel inlet filter block Panel/junction box open Screws missing Dust/dirt Connections with openwires
  38. 38. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – cables not routed properlyCables not routed properly Cables properly fixedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  39. 39. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – loose cables in the groundCables on the ground Cables laid properlyThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  40. 40. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – holes in the switch boxHoles in theswitch boxHoles fixedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  41. 41. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Abnormality – Earthing not doneEarthing not done Earthing doneThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  42. 42. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Step 4 – Check lists and Audit templates
  43. 43. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Template 1 – List of abnormalitiesVALVESThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  44. 44. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Template 2 – Check listsThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  45. 45. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Template 3 – Audit planThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  46. 46. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Template 4 – Status of the abnormalitiesRed Tag Status020406080Put 64 68 12 14 12 10 16 12 14Removed 62 64 10 11 10 8 10 14 16Dec06 Jan07Feb07IFeb07IIFeb07IIIFeb07IVMar07IMar07IIMar07IIINosThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  47. 47. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Template 5 - Break-down registerS.No MachineBreak-downreasonBreakdown time Machine up timeTime taken forrepairSpares changed Corrective Action Preventive Action1 Turret lathe Belt cut 10.30 AM 2.30PM 4 hrs Belt Regular checkingMonthly Audits andmonitoring the life time ofthe belt
  48. 48. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Step 5 – Visual Management
  49. 49. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Visual Management Bolt Alignment – look at themarkings for alignmentThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  50. 50. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Visual Management Markings to show theworking range Needle should always betweenthe red marks Look at the calibration datestickerThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  51. 51. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Visual Management Markings to show the levelof the grease in thereservoir. Look at the red, yellow andgreen levelsThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  52. 52. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Visual Management Visuals showing the details of Motor HP, Motor RPM, Sprocket and Chain Details Chain rotation direction and eye symbol for inspection areaThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  53. 53. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Visual Management Lever Open and Close markingsThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  54. 54. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.Visual Management Pressure markings in the pipesand the direction of flowThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  55. 55. MAINTENANCEMODULEAn initiative of Hash Management Services LLPA Business Sense PublicationFor more free resources visit www.businessense.inFor any queries / suggestions / requestsCall us: +91 91766 13965orEmail us: support@businessense.in

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