TPM: Planned Maintenance

2. © Operational Excellence Consulting. All rights reserved. 2 Learning Objectives Understand what is Planned Maintenance and why it is important in TPM implementation Describe the seven implementation steps of Planned Maintenance Acquire knowledge on how to plan and organize Planned Maintenance activities Gain knowledge on the JIPM TPM Excellence Criteria for Planned Maintenance NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg

3. © Operational Excellence Consulting. All rights reserved. 3 Contents What is Planned Maintenance? 2 Planning & Organizing for Planned Maintenance 3 The 7 Steps of Planned Maintenance 4 JIPM TPM Excellence Criteria for Planned Maintenance 5 Introduction to Planned Maintenance 1

4. © Operational Excellence Consulting. All rights reserved. 4 The Vicious Cycle Of Poor Equipment Reliability High frequency of equipment breakdowns Extensive emergency repairs No time for Planned Maintenance activities Fire-fighting ? UNHAPPY CUSTOMER POOR RELIABILITY Does your maintenance department look like this?

5. © Operational Excellence Consulting. All rights reserved. 5 From PM to TPM Productive Maintenance Preventive Maintenance TPM Traditional PM Centered in maintenance departments PM in TPM Everyone takes part Originated in the United States Developed in Japan (Commonly called “PM”) Source: Based on JIPM

6. © Operational Excellence Consulting. All rights reserved. 6 © Operational Excellence Consulting. All rights reserved. 6 “Minimizing manufacturing costs is achieved primarily by improving the productivity of all the machines on the factory floor, both bottleneck and non-bottleneck machines alike. This is a daunting challenge unless the entire organization pitches in and applies proven methods to the task.” JAMES A. LEFLAR Author of “Practical TPM”

7. © Operational Excellence Consulting. All rights reserved. 7 What Is TPM? TPM addresses the entire production system life cycle and builds a concrete, shop-floor based system to prevent all losses. Its aims include the elimination of all accidents, defects and breakdowns. The goal of TPM is to build a robust enterprise by maximizing production system efficiency (overall effectiveness) TPM involves all departments, from production to development, sales, and administration Everyone participates in TPM, from top executives to shopfloor employees TPM achieves zero losses, through overlapping team activities Maximize efficiency Entire equipment life cycle Coordinates all departments Involves everyone Team-based activities

8. © Operational Excellence Consulting. All rights reserved. 8 Planned Maintenance Is One Of The Foundational Pillars Of TPM Overview of TPM Office TPM Safety, Health & Environment Autonomous Maintenance Planned Maintenance Focused Improvement Early Equipment Management Quality Maintenance Education & Training 5S & Visual Management TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents Planned Maintenance aims to increase production efficiencies by eliminating breakdown losses.

9. © Operational Excellence Consulting. All rights reserved. 9 Difference Between Failure & Breakdown Failure § A failure occurs when equipment condition reaches an unacceptable level, even if it remains functional § This is a failure because even though the equipment is still functional, the subpar condition affects output and creates a precedent for breakdown — dubbed the failure developing period Breakdown § A breakdown occurs when the equipment stops functioning § Breakdown is the result of failure and the effect that failure has over the failure developing period § For example, if the temperature of your electric motor remains too high, it can cause the shaft to snap, creating a breakdown

10. © Operational Excellence Consulting. All rights reserved. 10 TPM – Three Principles Of Prevention Maintenance Of Normal Conditions To maintain normal operating conditions, operators prevent deterioration by cleaning, checking, oiling, tightening, and precision-checking the equipment on a daily basis Early Discovery Of Abnormalities While performing these activities, operators use their senses and measurement tools to detect abnormalities as soon as they appear. Maintenance workers also conduct periodic diagnostic tests to check for abnormalities using specialized tools. Prompt Response Operators and maintenance staff respond immediately to abnormalities

11. © Operational Excellence Consulting. All rights reserved. 11 What Is Planned Maintenance? Planned Maintenance is a proactive approach to maintenance that focuses on minimizing the downtime and costs associated with breakdowns.

14. © Operational Excellence Consulting. All rights reserved. 14 Difference Between Planned And Preventive Maintenance § The terms planned and preventive maintenance are often used somewhat interchangeably, but they are not the same thing § Preventive maintenance • Is the most common type of planned maintenance • It refers to maintenance tasks that you schedule and perform while an equipment is still working to prevent it from failing unexpectedly § Planned maintenance • Refers to any strategy where you plan and perform maintenance tasks before a fault occurs

15. © Operational Excellence Consulting. All rights reserved. 15 Difference Between Autonomous Maintenance and Planned Maintenance Autonomous Maintenance § Prevents accelerated deterioration of machine parts § Provides the underpinning to uphold the benefits of routine maintenance and Focused Improvement over the long term § Performed by operators Planned Maintenance § Prevents unplanned breakdown losses § Addresses specific equipment-related losses that reduce OEE § Uses data for analysis and planning § Performed by maintenance personnel

16. © Operational Excellence Consulting. All rights reserved. 16 Benefits of Planned Maintenance Reduces Spares Inventory Reduces inventory through better control of wear-prone and failure-prone parts Enables Maintenance Planning Enables most maintenance to be planned for times when equipment is not scheduled for production Reduces Unplanned Downtime Significantly reduces instances of unplanned downtime

17. © Operational Excellence Consulting. All rights reserved. 17 Policy of Planned Maintenance § Achieve and sustain availability of machines § Optimum maintenance cost § Reduces spares inventory § Improve reliability and maintainability of machines

18. © Operational Excellence Consulting. All rights reserved. 18 Planned Maintenance – Two Main Activities § Preventive Maintenance § Corrective Maintenance § Maintenance Prevention § Breakdown Maintenance § Support for Autonomous Maintenance § Specialized maintenance skills § Equipment repair skills § Inspection and measurement skills § Equipment diagnostic skills § Develop new maintenance technologies IMPROVEMENT OF EQUIPMENT à MTBF IMPROVEMENT OF MAINTENANCE SKILLS à MTTR

19. © Operational Excellence Consulting. All rights reserved. 19 Planned Maintenance Provides A System To Achieve The Natural Life Cycle Of Individual Equipment Elements § Correct operation § Correct set-up § Cleaning § Lubrication § Retightening § Feedback and repair of minor defects § Quality spare parts

20. © Operational Excellence Consulting. All rights reserved. 20 Elements Of A General Maintenance Plan 1. Maintenance vision and mission statements 2. Maintenance tasks 3. Standard operating procedures 4. Maintenance schedule 5. Maintenance staffing and skills development 6. Spare parts management 7. Engineering and third-party contractors

21. © Operational Excellence Consulting. All rights reserved. 21 TPM Implementation Organization Structure With Planned Maintenance Pillar TPM Responsible (Plant Manager) Planned Maintenance Focused Improvement Education & Training Autonomous Maintenance Safety, Health & Environment Early Equipment Management Office TPM Quality Maintenance TPM Promotion Office The company should focus on these four pillars during the first three years of TPM implementation

22. © Operational Excellence Consulting. All rights reserved. 22 Tasks for Maintenance Department § Tasks requiring special skills (beyond the capability of operators) § Overhaul repair in which deterioration is not visible from the outside § Repairs to equipment that is hard to disassemble and reassemble § Tasks requiring special measurements § Tasks posing substantial safety risks, such as working in high places Source: TPM for Workshop Leaders by Kunio Shirose

23. © Operational Excellence Consulting. All rights reserved. 23 Key Roles Of Operations & Maintenance Divisions Operations maximizes production outputs through efficient use of resources and takes responsibility for routine maintenance Maintenance increases equipment reliability and minimizes maintenance cost by reducing breakdowns and developing efficient maintenance methods Operations Maintenance Operations and Maintenance have tremendous ability to impact profitability through collaboration and change.

24. © Operational Excellence Consulting. All rights reserved. 24 Roles Of The Maintenance Department Figure 2: Roles of the Maintenance Department Maintenance Activities to be Performed Maintenance Classification Preventing Deterioration Measuring Deterioration Rectifying Deterioration Periodic Maintenance Periodic inspection Periodic examination Periodic shutdown Predictive Maintenance Trend control Unscheduled shutdown Sporadic repair Breakdown Maintenance Early detection of situation and speedy countermeasures Corrective Maintenance (Reliability) Enhancement of material strength Reduction of load Enhancement of accuracy Corrective Maintenance (Maintainability) Development of condition monitoring Improvement of maintenance work Improvement of inspection work Enhancement of maintenance quality

25. © Operational Excellence Consulting. All rights reserved. 25 Maintenance & Control § Improvements in MTBF are accomplished through the support of AM activities and the implementation of the four maintenance types discussed previously: • Breakdown maintenance • Periodic maintenance • Predictive maintenance • Corrective maintenance

26. © Operational Excellence Consulting. All rights reserved. 26 The 4 Phases to Zero Breakdowns Phase 1 Eliminate forced deterioration Phase 2 Extend lifetimes through corrective maintenance Phase 3 Monitor and control deterioration Phase 4 Carry out predictive maintenance

27. © Operational Excellence Consulting. All rights reserved. 27 The 7 Steps Of Planned Maintenance Provide Support And Guidance To Autonomous Maintenance Activities Evaluate Equipment And Understand Current Condition Restore Deterioration And Correct Weaknesses Build An Information Management System Build A Periodic Maintenance System Build A Predictive Maintenance System Evaluate The Planned Maintenance System 1 2 3 4 5 6 7

28. © Operational Excellence Consulting. All rights reserved. 28 Step 3 – Restore Deterioration And Correct Weaknesses § Extend help to operators to prepare ‘tentative standards’ for cleaning, lubrication and inspection for each machine § Specify clearly what the operators are supposed to do under Autonomous Maintenance and what the maintenance engineers are supposed to do under Planned Maintenance § Use provisional standards for checking and replacement intervals § Examine each machine and identify the parts that should be subjected to preventive maintenance § Establish schedules for TBM and CBM

29. © Operational Excellence Consulting. All rights reserved. 29 How to Sustain TPM & Planned Maintenance Activities § Providing active leadership § Engaging employees § Aim for early success § Share success stories § Rewards and recognition § Continuously reduce equipment losses § Evolving the TPM initiative over time and integration with Lean

30. © Operational Excellence Consulting. All rights reserved. 30 Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. Based in Singapore, the firm’s mission is to create business value for organizations through innovative design and operational excellence management training and consulting solutions. For more information, please visit www.oeconsulting.com.sg

TPM: Planned Maintenance

You are reading a preview.

Check these out next

TPM: Planned Maintenance

More Related Content

More from Operational Excellence Consulting (Singapore) (20)

Recently uploaded (20)