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Preventive / Autonomous Maintenance - Beginners Guide - Tamil
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Preventive / Autonomous Maintenance - Beginners Guide - Tamil

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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 …

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.

This presentation is in Tamil Language. Please visit www.businessense.in to download this document.

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  • 1. MAINTENANCEMODULEIN TAMILAn initiative of Hash Management Services LLPA Business Sense PublicationFor more free resources visit www.businessense.in
  • 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. 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 என்பது அனைத்து machines and equipments சரியாகவேனல சசய்ேனை ensure சசய்ைிட வேண்டும் Maintenance function, spares மற்றும் consumablesஐ plan சசய்து ோங்கநடேடிக்னக எடுக்க வேண்டும் layout change சசய்யும் வபாது machines and equipmentsஐ நகர்த்துேைற்கும்,wiring சசய்ேைற்கும், சேளியாட்களுடன் co-ordinate சசய்ோர்கள் அனைத்து machinesகளும் breakdown ஆகாமல் பாதுகாக்க வேண்டும்
  • 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 functionகீழ் ேருேை Maintenance Functionன் முக்கியமாை சபாறுப்புகள் ஆகும் Machineஐ Basic conditionல் னேத்து இருப்பது Machineகனள Higher Levels of Performanceக்கு எடுத்து சசல்ேது Zero Failures , Zero Defects & Zero Accidents ஆக சசயல்படுேது There are 2 basic types of maintenance Break-down Maintenance –Machine break down ஆை பின் சசய்ேது Preventive Maintenance –Machine break down ஆேைற்கு முன் சசய்ேது -Maintenance team ஆல் சீராை இனடசேளியில்சசய்யப்படுேது - to keepthe machineஐ working conditionல் னேத்ைிருப்பைற்கு Autonomous Maintenance (AM) is a part of Preventive Maintenance (PM) AM என்பது machine Operatorவர சசய்ய வேண்டிய வேனலகள் ஆகும் இேற்னற கனடபிடித்ைால், Break-downs of machines zero ஆகி ேிடும்MaintenancePreventiveMaintenanceAutonomousBreakdownMaintenance
  • 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 ஑ரு machine break downஆைவுடன், அந்ை operator, productionsupervisorரிடம் complaint சசய்து Maintenance teamஐ ேரனேப்பார் Maintenance team ேந்ைவுடன் machineஐ சரி பார்பர் நினறய companyகளில், Maintenance teamமுடன் Service Level Agreementஏற்படுத்ைியிருப்பார்கள் ( e.g. maintenance team personnel 30 நிமிடங்களில் machineஐஅனடய வேண்டும் )
  • 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 இது maintenance teamஆல் சசய்யப்படும் schedule based maintenance program ஆகும் Daily / weekly / fortnightly / monthly / quarterly plan for all machines A preventive Maintenance calendar அனைத்து machineகளுக்கும் ையாரித்து ஒவ்சோருmachineக்கும் ஑ருேனர சபாறுப்பாளராக நியமிக்க வேண்டும்
  • 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) Operatorகள் அேர்களாகவே சசய்ேைாகும் Cleaning / Lubrication / Re-tightening / Inspection வபான்றனே இைில் அடங்கும் சிறு spare change வபான்றனேயும் இைில் அடங்கும்
  • 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.AM சசய்யும் முனறகள்1. Preparation / ையார் சசய்ைல்2. Cleaning and Inspection / சுத்ைம் & Inspection சசய்ைல்3. Eliminate Problem Sources and abnormalities4. Cleaning, Lubrication, Re-tightening, Inspection – Checklistsand 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. 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 / ையார் சசய்ைல்Step 2 – Initial Cleaning & Inspection / சுத்ைம்& Inspection சசய்ைல்
  • 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 / ையார் சசய்ைல் ஒவ்சோரு machineைின் functionஐ அறியவும் ஒவ்சோரு machineைின் safety aspectகனள அறியவும் Operator களுக்கு machineகனள பற்றி எடுத்துக்கூறவும் ஒவ்சோரு Machine partsஐயும் Identify சசய்து அைன் சசயல்பாட்னடயும்,பயன்கனளயும் அறியவும்Knowing the machine & itsparts is the primary step
  • 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 Machineஐ சுத்ைமாக துனடக்கவும் கீழ் ேருேைேற்னற கேைிக்கவும்: Abnormality Hard to Access area Source of Contamination & Localization Unsafe Conditions
  • 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.Machineஐ துனடப்பது Cleaning சசய்ேைற்கு முன், எல்லா WIPmaterialகனளயும் முழுைாக cover சசய்ய வேண்டும் 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. 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 எங்கு கண்டுபிடிப்பது ?
  • 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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 –alignmentmarkingகனள கேைிக்கவும்These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 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 Working rangeஐகாட்டுேைற்காக உள்ளMarkingஐ கேைிக்கவும் Needle எப்சபாழுதும் redmarks’க்குள் ைான் இருக்கவேண்டும் Calibration date stickerஐகேைிக்கவும்These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 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 Grease level ஐகாண்பிப்பைற்காக உள்ளmarkingsஐ கேைிக்கவும் Red, yellow and green levelகனளகேைிக்கவும்These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 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 Motor HP, Motor RPM, Sprocket and Chain Detail வபான்றேற்றின் stickerகனளகேைிக்கவும் 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. 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 Closemarkingகனள கேைிக்கவும்These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 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 flowஐகேைிக்கவும்These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 55. An 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.inMAINTENANCEMODULEIN TAMIL