1. The Essentials - Maintenance
HASH MANAGEMENT SERVICES LLP
CHENNAI
PH: 91766 13965

2. Overview
 ‘The Essentials’ series from Business Sense is an initiative to empower the students(freshers) and
professionals in performing more efficiently and effectively in the organization
 This document is a part of the “Certified Manufacturing Professional” course offered by Business Sense
 This course is aimed at bridging the gap between the institutions and the industry by providing the
fundamentals of manufacturing management which are not offered by any of our
institutions/curriculum
 This course would immensely benefit students and professionals who are joining manufacturing
organizations
 For more details, please visit www.businessense.in
 At Business Sense, we help clients through consulting engagements focusing on improving their
Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools.
 We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply
Chain Re-engineering.
 You can subscribe to our bi-weekly newsletter here.
 Follow us:
Copyright of Hash Management Services LLP www.businessense.in

3. Contents
 Section 1 – Introduction and Basic Processes
 Section 2 – Autonomous Maintenance
 Section 3 – Pictorial Representations
Copyright of Hash Management Services LLP www.businessense.in

4. Introduction to Maintenance Function
 Maintenance function ensures that all the machines and equipments related to
the production 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
Copyright of Hash Management Services LLP www.businessense.in

5. Responsibilities of an Engineer in the
Maintenance Function
 To bring the machine to the working condition, in case of a break-down
 Improving the performance of the machines to the specified levels of
performance
 To Move towards Zero Failures , Zero Defects & Zero Accidents
 Analyzing and stocking the Vital, Essential and Desired spares through VED
Analysis
 Maintaining a MIS report of Break-down register and Preventive Maintenance
schedule
 Coordinating and supporting during layout changes and new machine
installations
Copyright of Hash Management Services LLP www.businessense.in

6. Types of Maintenance
 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 the Maintenance team at
regular intervals to keep the machine in working condition
 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!
Copyright of Hash Management Services LLP www.businessense.in

7. Break-down Maintenance
 Once a particular machine breaks down, the operator informs the
production 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 team
to attend the machines ( e.g. maintenance team personnel should reach the
machine with in 30 min )
Copyright of Hash Management Services LLP www.businessense.in

8. Preventive Maintenance
 This is a schedule based maintenance program which would be done by
the maintenance team
 Daily / weekly / fortnightly / monthly / quarterly plan for all machines
 A preventive Maintenance calendar should be created covering all
major machines in the company and person responsible for the same
Copyright of Hash Management Services LLP www.businessense.in

9. Autonomous Maintenance (AM)
 Would be done by the operator themselves
 Cleaning / Lubrication / Re-tightening / Inspection are covered under
Autonomous Maintenance
 Minor spare change can also be covered under AM
Copyright of Hash Management Services LLP www.businessense.in

10. Steps for Implementing AM
1. Preparation
2. Cleaning and Inspection
3. Eliminate Problem Sources and abnormalities
4. Cleaning, Lubrication, Re-tightening, Inspection – Checklists and Audits
5. Visual Management
 Please note that this list covers only the basics. This is not the
exhaustive list of steps as prescribed by the TPM model
Copyright of Hash Management Services LLP www.businessense.in

11. 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 machine
Knowing the machine & its parts is the primary step
Copyright of Hash Management Services LLP www.businessense.in

12. Step 2- Cleaning and Inspection
 Initial Cleaning of the Machine
 Identification of
 Abnormality
 Hard to Access area
 Source of Contamination & Localization
 Unsafe Conditions
Copyright of Hash Management Services LLP www.businessense.in

13. Step 2- Initial Cleaning of the Machine
 Before cleaning, all WIP materials in the machine to be properly covered.
 Cleaning Agent should be applied as mentioned in the manual of the machine
only
 Cleaning tools:
 Cotton Waste
 Tool Box / Trolley
 Wire Brushes
 Ladder , Screw Driver
 Emery Sheet - Medium
 Cleaning Agent – Kerosene , Soap oil
Copyright of Hash Management Services LLP www.businessense.in

14. Step 2- Identification of Abnormality
Abnormalities Where to find them?
 Dust  Non standard  Bolts and nuts/ joints
 Dirt  Vibration  Lubrication
 Leak  Noise  Transmission
 Rust
 Misalignment  Hydraulics
 Loose
 Shaking  Pneumatics – gas system
 Damage
 Deformed  Worn out  Electrical
 Missing  Safety
Copyright of Hash Management Services LLP www.businessense.in

15. Step 3 – Elimination of abnormalities
Missing Nut Nut fixed
Copyright of Hash Management Services LLP www.businessense.in

16. Step 3 – Elimination of abnormalities
Different Nuts Same type nuts
Remaining steps with pictures and Report templates are explained in the “Certified Manufacturing
Professional” course. To access login to www.businessense.in
Copyright of Hash Management Services LLP www.businessense.in

17. End of Free Content
 Please visit our website www.businessense.in to access the full course – “Certified Manufacturing
Professional”
 Our website also contains list of ready-to-use templates and report formats containing Charts and
pivot tables.
 Templates and report formats are available for Purchase, Stores, Production, Quality, Maintenance and
HR functions
 These templates come in excel /word and can be downloaded and used right away
 At Business Sense, we help clients through consulting engagements focusing on improving
their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and
other tools.
 We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and
Supply Chain Re-engineering.
 You can subscribe to our bi-weekly newsletter here.
 Follow us:
Copyright of Hash Management Services LLP www.businessense.in