The document discusses establishing standards for equipment preventive maintenance through steps like identifying areas for cleaning, lubrication, inspection and tightening, deciding tools and methods, setting goals and timelines, introducing visual controls, and preparing standards that can be easily followed to help maintain equipment in optimal condition and prevent failures. It provides examples of potential standards for cleaning, lubrication and inspection activities.

1. Mr. Deepak Sahoo
Consultant

2. •To PREVENT EQUIPMENT DETERIORATION
•TO MAINTAIN EQUIPMENT IN OPTIMAL CONDTION
•TO ESTABLISH BASIC EQUIPMENT CONDITION
•TO ELIMINATE EQUIPMENT FAILURE
•TO MAKE OPERATOR EQUIPMENT COMPETENT
•TO ELIMINATE Quality Defects
•TO ELIMINATE COST LOSSES
Mr. Deepak Sahoo
Consultant

3. EQUIPMENT DETERIORATION
Natural Deterioration Accelerated Deterioration
Extend Life Time Eliminate Causes
Corrective Maintenance Establish Basic Condition
• Prevent errors by • Cleaning : Eliminate
improving operability all dust & Dirt
•Improve Maintainability • Lubricating : Keep
& Repair Quality lubricants clean and
• Improve safety replenished
& Reliability • Tightening : Keep nuts
& bolts secure
Mr. Deepak Sahoo
Consultant

4. Mr. Deepak Sahoo
Consultant

5. PREVENTIVE MEDICINE FOR EQUIPMENT =
PREVENTIVE MAINTENANCE
Preventive
Medicine
Health
Daily Early
checkup
Prevention treatment
(Diagnosis)
Prevents Measures Repair
deterioration deterioration deterioration
Daily maintenance Make preventive
Inspection
(lubricate, clean, repairs (advance
(Diagnosis)
adjust, inspect replacement)
Preventive
Maintenance Mr. Deepak Sahoo
Consultant

6. CLASSIFICATION OF MAINTENANCE ACTIVITIES
Normal operation
Daily maintenance
Maintain Preventive
maintenance Periodical maintenance
preventing & Predictive maintenance
repairing failure
Breakdown maintenance
Maintenance
activities
Corrective maintenance
Improvement of maintainability
Improvement of reliability
Improve
Prolong equipment life
Eliminate maintenance Maintenance prevention
Reduce maintenance hours Design which does not need maintenance
Mr. Deepak Sahoo
Consultant

7. CLASSIFICATION OF DEFECTS
Physical latent defects Psychological latent defects
The defects which are left unattended Defects which are left unnoticed due to
since they are not physically exposed to insufficient knowledge and education of
naked eyes operators or maintenance people
1. Defects which can not be visually 1. Operator or maintenance man’s
observed unless the equipment is indifference
dismantled
2. Defects which can not be visually 2. Operator or maintenance man is not well
noticed due to improper installation familiarized with types of defects
location of equipment
3. Defects which are likely to be ignored 3. Operator or maintenance man’s ignorance
since they are covered with dust or they based on their own judgment
are heavily soiled
Mr. Deepak Sahoo
Consultant

8. 1.MINOR FLAWS
2. UNFULFILLED BASIC CONDITIONS
3. INACCESSABLE PLACES
4. CONTEMINATION SOURCES
5. QUALITY DEFECT SOURCES
6. UNNECCERY AND NON-URGENT ITEMS
7. UNSAFE PLACES
Mr. Deepak Sahoo
Consultant

9. 1.MINOR FLAWS :
Contamination Dust, Dirt, powder, oil, grease, rust, paint
Damage Cracking, crushing, deformation, chipping,
bending,
Play Shaking, falling out, tilting, eccentricity, wear,
distortion, corrosion,
Slackness Belts, Chains
Abnormal Unusual noise, overheating, Vibration, strange
Phenomenon smells, discoloration, incorrect pressure or
current
Adhesion Blocking, hardening, accumulation of debris,
peeling, malfunction
Mr. Deepak Sahoo
Consultant

10. 2. UNFULFILLED BASIC CONDITIONS
Lubrication Insufficient, Dirty, Unidentified, unsuitable,
Leaking
Lubrication Dirty, damaged or deformed lubricant inlets,
Supply faulty lubricant pipes
Oil level gauges Dirty, Damaged, leaking, No indication of
correct level
Tightening Nuts and Bolts slackness, Missing, Cross-
threaded, Too long, Crushed, Corroded,
Unsuitable washers, wing nuts on backward
Mr. Deepak Sahoo
Consultant

11. 3. INACCESSABLE PLACES
Cleaning Machine construction, Covers, Layout, footholds,
Space
Checking Construction, Covers, Layout, footholds,
Instrument position and Orientation, Operating –
Range display
Lubricating Position of lubricant inlet, construction, height,
footholds, lubricant outlets, space
Tightening Covers, Construction, Layout size, Space
Operation Machine layout, Position of valves, Switches and
leavers, Footholds
Adjustment Position of pressure gauges, thermometers, flow
meters, moisture gauges, vacuum gauges, etc.
Mr. Deepak Sahoo
Consultant

12. 4. CONTEMINATION SOURCES
Product Leaks, Spills, Spurts, Scattering, Overflow
Raw materials Leaks, Spills, Spurts, Scattering, Overflow
Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids,
Fuel oils, etc.
Gases Leaking compressed air, gases, steam, vapors,
exhaust fumes, etc.
Liquids Leaking water, Hot, Cold, half finished
products, Waste water, Leaking supply lines etc.
Scrap Flashes, cuttings, packaging materials, and non
conforming products.
Others Contaminants by people & Forklifts, Infiltration
through cracked walls, broken windows etc.
Mr. Deepak Sahoo
Consultant

13. 5. QUALITY DEFECT SOURCES
Foreign Matter Dust, Rust, powder, chips, moisture, wire
scraps, wood pieces, paper pieces, stones etc.
Shock Dropping, Jolting, collision, Vibration etc.
Moisture Too little or Too much, infiltration
Gain Size Abnormalities in screens, Compressed air
separators, centrifugal separators,
Concentration Inadequate warming, heating, compounding,
mixing, evaporation, stirring etc.
Viscosity Inadequate warming, heating, compounding,
mixing, evaporation, stirring etc.
Mr. Deepak Sahoo
Consultant

14. 6. UNNECCERY AND NON-URGENT ITEMS
Machinery Pumps, fans, compressors, columns, tanks etc.
Piping equipment Pipes, hoses, ducts, valves, dampers etc.
Measuring Temperatures, pressure gauges, vacuum
instruments gauges, ammeters etc.
Electrical Wiring, piping, power leads, switches, plugs
equipment etc.
Jigs & Tools General tools, cutting tools, jigs, molds, dies,
frames etc.
Spare parts Standby equipment, spares, permanent stocks,
auxiliary materials, etc.
Makeshift repairs Tape. String, wire, metal plates etc.
Mr. Deepak Sahoo
Consultant

15. 7. UNSAFE PLACES
Floors Unevenness, cracked, holes, projections, peeling,
wear of steel chucker plates, slipping.
Steps Too steep, irregular, slipping, missing handrails, etc.
Lights Dim, out of position, dirty or broken covers, no
explosion proofing, etc.
Rotating Displaced, fallen oil or broken covers, not safe for
machinery emergency, missing emergency stop devices
Lifting Wires, hooks, brakes and other parts of cranes and
Devices hoists etc.
Others Special substances, solvents, toxic gases, insulating
materials, danger signs, protective clothing etc.
Mr. Deepak Sahoo
Consultant

16. 7 Steps of Autonomous Maintenance
Autonomous Management
Standardization
Autonomous Inspection
General Inspection
Preparing Tentative Cleaning, Lubrication, Inspection & Retightening Stds.
Countermeasures against Sources of contamination & Hard to Access areas
Initial thorough Cleaning
Preparation Mr. Deepak Sahoo
Consultant

17. Z
E • PREPARE A CLEANING & LUBRICATION MAP
R • ARRANGE TOOLS
O • ARRANGE RED & WHITE TAGS
S • HISTROY OF FAILURES
T • TRAINING ON 7 STEPS OF JISHU HOZEN
E • TRAINING ON 7 TYPES OF ABNORMALITIES
P
Mr. Deepak Sahoo
Consultant

18. • CLEANING IS INSPECTION
• USE 5 SENSES FOR CLEANING
• FIND OUT 7 TYPE OF ABNORMALITIES
• PUT TAGS ON ABNORMALITIES
• PREPARE LIST OF UNFULFILLED BASIC
CONDITIONS
Mr. Deepak Sahoo
Consultant

19. White tags for operators Red Tags to be attended by Maint.
Equipment Name ……………… Equipment Name ………………
Control No…………………….. Control No……………………..
Date of detection………………. Date of detection……………….
Detected by…………………….. Detected by……………………..
Description of Minor defects Description of Minor defects
…………………………………. ………………………………….
………………………………….. …………………………………..
…………………………………. ………………………………….
Mr. Deepak Sahoo
Consultant

20. • MAKE THE LIST OF
• HARD TO CLEAN,
• HARD TO LUBRICATE,
• HARD TO TIGHTEN, Areas / Parts
• HARD TO INSPECT,
• HARD TO ADJUST
•RECORD CLEANING TIME
• CARRY OUT AUDIT ON 1ST STEP
• MEETING AFTER THE DAILY ACTIVITIES
• REFER TO THE OLD HISTORY RECORDS
Mr. Deepak Sahoo
Consultant

21. Mr. Deepak Sahoo
Consultant

22. Mr. Deepak Sahoo
Consultant

23. Mr. Deepak Sahoo
Consultant

24. EXAMPLE OF ABNORMALITY
( LOOSE FITTINGS )
Mr. Deepak Sahoo
Consultant

25. EXAMPLE OF ABNORMALITY
( LEAKAGES )
Mr. Deepak Sahoo
Consultant

26. RELAY
TRAINING
Mr. Deepak Sahoo
Consultant

27. Purpose of Step-2
Eliminate sources of Contamination
To improve places where it is difficult to access for cleaning, lubrication,
inspection
Improved maintainability of Equipment
Enable Learning in tackling Equipment Kaizen
Mr. Deepak Sahoo
Consultant

28. COUNTERMEASURES AGAINST SOURCES
STEP 2 OF CONTEMINATION AND HARD TO DO
CLITA
• COUNTERMEASURES AGAINST SOURCES OF
CONTAMINATION
• MAKE APPROACH EASY FOR CLITA
• MAKE EASY TO DO CLITA
• SHORTEN CLEANING , LUBRICATING TIME
• ADOPT CONCEPTS OF LOCALIZED GUARDS
• RANKING THE PRIORITY PLACES FOR DAILY
CLEANING
Mr. Deepak Sahoo
Consultant

29. Finding & Confirmation Hard to Access Areas
of Generating Sources
•Understand contaminations relationship •Time consuming Places
with Quality, Failures, Maintainability •Places difficult to do.
etc.
•Locate contamination generating sources
Analysis of Analyzing
Generating Sources Hard to Access areas
•Understand why do they generate? • What type of work is performed?
•Impact on Equipment • What tools are used?
•Confirm the basic countermeasures • Can work be performed in visible state?
Mr. Deepak Sahoo
Consultant

30. Devising countermeasures Hard to Access Areas
to Eliminate
Sources of Contamination Time consuming Places
•Places difficult to do.
Eliminate the Source
Eliminate Need to Access
Contain (localize)
the Contaminant
Reduce Improved
need to Method of
Shield (Protect) the
(Frequency) C, L, I & R
Affected part
approach Less Time & Effort
Improve
Improve Accessibility
Cleaning Method Mr. Deepak Sahoo
Consultant

31. Easy to clean
Mr. Deepak Sahoo
Consultant

32. SOURCE OF CONTAMINATIONS
Mr. Deepak Sahoo
Consultant

33. Usage of localised guards
Mr. Deepak Sahoo
Consultant

34. Easy to lubricate
Mr. Deepak Sahoo
Consultant

35. Countermeasures against source of contamination
Oil Localisation
Before After
Localised gaurds
The return oil flow from the feed drive gears splash and spread all around the
open space inside the machine there by getting contaminated. To avoid the
contamination, the return oil flow is channalised from the feed drive gears
directly to the lubrication tank
Mr. Deepak Sahoo
Consultant

36. DIFFICULT TO LUBRICATE
- EASY TO LUBRICATE
Before After
Difficult to Lubricate the oil to Easy to Lubricate the oil to
gear box gear box
Mr. Deepak Sahoo
Consultant

37. Easy to Inspect
Mr. Deepak Sahoo
Consultant

38. THEME: LOSS NO.
KAIZEN MACHINE: 10B3S
KAIZEN START
LOSS STRUCTURE: TEAM: J. Sriram
To reduce Inspection time
8A Inspection Time Reduction
Karunairaja 10.05.2001
Franklin KAIZEN FINISH
BENCH MARK 30 sec / Day IDEA:
To bring the pressure gauge for K.O. system outside the Sivakumar 25.05.2001
TARGET 2 sec / Day machine for easy inspection
Ramalingam
PROBLEM: COUNTERMEASURE: BENEFITS :
Before After
Time saving = 28 sec / Day
Man hours saved per year = 15 hours
Inspection is very difficult and
taking more time in the pressure Pressure Other Benefits
gauge for K.O. system Pressure
gauge Inspection becomes easy
gauge
Inside the M/c
Outside the M/c
Difficult to Easy to
Inspect Inspect
ANALYSIS: Problem : Inspection is difficult RESULT: HORIZONTAL DEPLOYMENT :
WHY 1 WHY 2 WHY 3
Sec.
By machine 30 sec / change
Pressure gauge 30
Inspection is Better
kept inside the design
very difficult No of Areas
and it is machine
taking 15 Identified : 5 Nos.
moretime in
pressure Implemented : 5 Nos.
2 sec / Day
gauge for 0
K.O. system Before After
Mr. Deepak Sahoo
Consultant

39. Mr. Deepak Sahoo
Consultant

40. DIFFICULT TO INSPECT- EASY TO INSPECT
Before After
Difficult to Inspect the belt Easy to Inspect the belt condition
condition
Mr. Deepak Sahoo
Consultant

41. Purpose of Step-3
Continuously Maintaining and Management of Basic equipment conditions,
(I.e. Cleaning, Lubrication, Retightening)
Enhancing Equipment Reliability & Maintainability
Preparing standards that can be followed easily
Ideas for Visual Improvement
Mr. Deepak Sahoo
Consultant

42. Cleaning, Inspection, Lubrication & Retightening
Clarification of places & location by all
Deciding tools, jigs to be used
Decided the method
Decide Standard / Level
Identify Problems & decide Trouble Shooting
Clarify Period
Set Goal Time
Use of Visual Control
Visual ways to allow correct
decision in short span of time on Prepare Standards &
the spot by only seeing Calendar (Schedule)
Mr. Deepak Sahoo
Consultant

43. C, L, I, R Standards
Implementing Cleaning, Lubrication,
Inspection, & Retightening
Difference with Goal Time
Kaizen (Implement & Confirm)
Feedback Audit
Passed Mr. Deepak Sahoo
Consultant

44. STEP 3
• STANDARDS FOR CLEANING, LUBRICATING
AND TIGHTENING
• STANDARDS ARE MADE BY OPERATORS
THEMSELVES WITH GUIDENCE BY PM
• STANDARDS ARE MADE BY USING 5W 1H
• STANDARDS SHOULD BE EASILY UNDERSTOOD
BY EVERY ONE
• INTRODUCE EXTENSIVE VISUAL CONTROLS
Mr. Deepak Sahoo
Consultant

45. CLEANING LUBRICATION & INSPECTION STANDARDS
Cleaning activities : Lubrication activities : Inspection activities :
Remarks
Sl. Route Sub - Responsibility
Criteria Where What How Time (Impact of
No. Reference Assembly (Who)
overlooking)
Dual Ext.
1 Cleaning Steel belt Dust & dirt 20 Sec Operator Quality defect
steel belt
Dual Ext. Driven roll Equipment
2 Lubrication EP-2 grease 30 Sec Operator
skiver bearing failure
Inside pull
3 Inspection Head stock No damage 5 Sec Operator UNSAFE
out ring
Mr. Deepak Sahoo
Consultant

46. VISUAL CONTROLS
Activity Symbol Tools
CLEAN
I
LUB
S
INSPECTION NOC
Mr. Deepak Sahoo
Consultant

47. Indication marks
Indication for
for nuts & bolts
valve controls
Mr. Deepak Sahoo
Consultant

48. Arrow sign for
Fan to indicate the
indicating the
function of Chiller Unit
rotating direction of
Motor
Mr. Deepak Sahoo
Consultant

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Consultant

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Consultant

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Consultant

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Consultant

53. Avoid such extremes with some over enthusiastic teams
Mr. Deepak Sahoo
Consultant

54. Purpose of Step-4
Bringing up equipment consciousness in the process of measuring & restoring
deterioration.
To understand structures, functions & principles of equipment & learn their
optimal conditions to thoroughly check principal mechanisms & parts of the
equipment
Mr. Deepak Sahoo
Consultant

55. Preparation for Education & Training
Identifying general Inspection Items
Basic Items:
Machine Elements Lubrication system Bolts & Nuts
Hydraulic System Pneumatic System Driving Systems
Electrical systems Equipment Safety Process Conditions
Additional Items: Specific to the Equipment
Preparation of text for General Inspection Education & Training
Schedule Planning for General Inspection Education & Training
Mr. Deepak Sahoo
Consultant

56. Implementation of General Inspection
Education & Training
Implementation of Education for Circle Leaders
Preparation of education transmission to Circle Members
Implementation of education transmission to Circle Members
Implementation of General Inspection
Implementation of General Inspection
Preparation of Abnormalities List for Circle Meetings
Discussion & Planning Countermeasures
Restoration of Abnormalities List Mr. Deepak Sahoo
Consultant

57. Prevention of Irregularities in General Inspection Items
Preparation of Temporary Criteria for Daily Inspection
Inspection skill Check
Autonomous Audit & Application for receiving diagnosis
Implementation of Audit
Solutions to the Items Pointed out
Mr. Deepak Sahoo
Consultant

58. Prevention of Irregularities in General Inspection Items
Preparation of Temporary Criteria for Daily Inspection
Inspection skill Check
Autonomous Audit & Application for receiving diagnosis
Implementation of Audit
Solutions to the Items Pointed out
Mr. Deepak Sahoo
Consultant

59. Initial Clean-up
( Cleaning is Inspection)
( Cleaning with meaning)
(Doing with purpose)
Taking countermeasure
for forced deterioration
and improving hard
to access area
Preparing tentative
standards for cleaning
and lubrication
Mr. Deepak Sahoo
Consultant

60. Four Steps to Become An Operator Strong on
Equipment And Autonomous Maintenance
Autonomous Four steps to
Maintenance become an operator
7 steps strong on equipment
7 All-out autonomous management 4 Master how to repair the equipment
Learn how to operate the
6 Orderliness and tidiness equipment with the required
3
accuracy and how to evaluate
the product quality
5 Autonomous check-up
4 General inspection Study the mechanism and
2 functions of equipment and
3 Formulation of clean-up and lubrication
standards machines
2 Measures against sources of outbreaks Familiarize with the concept of
equipment maintenance and
1
improvement and with how to put the
1 Initial clean-up idea into practical realization
Mr. Deepak Sahoo
Consultant