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Preventive / Autonomous Maintenance - Beginners Guide - Tamil

இந்த ஆவணத்தில், இயந்திர பராமரிப்பு செயல்முறை மற்றும் அதன் முக்கியத்துவம் விளக்கப்படுகிறது, மேலும் பராமரிப்பின் வகைகளைப் புகாரளிக்கிறது: உடைப்புப் பராமரிப்பு மற்றும் முன்ன preventative பராமரிப்பு. இயந்திரங்களைப் பாதுகாப்பதற்கான பேராசிரியர்கள் மற்றும் தொழில்முறை நுட்பங்கள் குறித்து விவாதிக்கப்பட்டுள்ளது, மேலும் நவீன மின்சக்தி மற்றும் எடை வடிகட்டல் சாமான்களுக்கான குறைகள் அடையாளங்காணப்படும். தொழில்நுட்ப உறுப்பினர்கள் இயந்திரப் பராமரிப்பை மேம்படுத்துவதற்காகப் பரிந்துரைகள் மற்றும் அறிக்கைகள் வழங்கப்படுகின்றன.

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MAINTENANCE MODULE IN TAMIL An initiative of Hash Management Services LLP A Business Sense Publication For more free resources visit www.businessense.in
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 more efficiently and effectively in the organization  This publication 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 professionals and students who are joining manufacturing organizations  At Business Sense, we help medium scale manufacturing units improve their operational efficiency through consulting engagements 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 day and 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:
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 சரியாக வேனல சசய்ேனை ensure சசய்ைிட வேண்டும்  Maintenance function, spares மற்றும் consumablesஐ plan சசய்து ோங்க நடேடிக்னக எடுக்க வேண்டும்  layout change சசய்யும் வபாது machines and equipmentsஐ நகர்த்துேைற்கும், wiring சசய்ேைற்கும், சேளியாட்களுடன் co-ordinate சசய்ோர்கள்  அனைத்து machinesகளும் breakdown ஆகாமல் பாதுகாக்க வேண்டும்
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 கீழ் ே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 keep the 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 ேிடும் Maintenance Preventive Maintenance Autonomous Breakdown Maintenance
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, production supervisorரிடம் complaint சசய்து Maintenance teamஐ ேரனேப்பார்  Maintenance team ேந்ைவுடன் machineஐ சரி பார்பர்  நினறய companyகளில், Maintenance teamமுடன் Service Level Agreement ஏற்படுத்ைியிருப்பார்கள் ( e.g. maintenance team personnel 30 நிமிடங்களில் machineஐ அனடய வேண்டும் )
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 ஒவ்சோரு machineக்கும் ஑ருேனர சபாறுப்பாளராக நியமிக்க வேண்டும்
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
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 முனறகள் 1. Preparation / ையார் சசய்ைல் 2. Cleaning and Inspection / சுத்ைம் & Inspection சசய்ைல் 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
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 Step 2 – Initial Cleaning & Inspection / சுத்ைம் & Inspection சசய்ைல்
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 அறியவும் Knowing the machine & its parts is the primary step
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
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 WIP materialகனளயும் முழுைாக cover சசய்ய வேண்டும்  Cleaning tools:  Cotton Waste  Tool Box / Trolley  Wire Brushes  Ladder , Screw Driver  Emery Sheet - Medium  Cleaning Agent – Kerosene , Soap oil These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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  Missing Abnormalities எங்கு கண்டுபிடிப்பது ?
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
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
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 Nut Missing Nut Nut fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 screw Missing Screw Screw fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 nut Different Nuts Same type nuts These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 bolt Bolt head painted! Difficult to remove the bolt in future Paint removed from the bolt head These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 bolt Bend in the bolt New bolt and nut fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 washers Different washers used Washers fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 thread Rust in the bolt thread Rust removed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 Contamination These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 reservoir No grease Grease filled These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 visible Grease level not visible Grease level visible These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 grease Excess grease Optimal grease These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 / shaft damaged  Belt missing  Tracking  Eccentricity  Play
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 - slackness Slackness in belt Slackness removed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 available Cooling fan – not available Cooling fan fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 available Chain guard – not available Chain Guard - fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 leakage Oil Leakage from the machine Oil Leak fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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
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 working Gauge damaged / not working Gauge repaired These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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
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 leakage Air leakage Leakage arrestedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 leakage Steam leakage Steam Leakage arrested These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 more heat  Exposed wires  Panel inlet filter block  Panel/junction box open  Screws missing  Dust/dirt  Connections with open wires
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 properly Cables not routed properly Cables properly fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 ground Cables on the ground Cables laid properly These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 box Holes in the switch box Holes fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 done Earthing not done Earthing done These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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
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 abnormalities VALVES These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 lists These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 plan These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 abnormalities Red Tag Status 0 20 40 60 80 Put 64 68 12 14 12 10 16 12 14 Removed 62 64 10 11 10 8 10 14 16 Dec'06 Jan'07 Feb'07 I Feb'07 II Feb'07 III Feb'07 IV Mar'07 I Mar'07 II Mar'07 III Nos These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 register S.No Machine Break-down reason Breakdown time Machine up time Time taken for repair Spares changed Corrective Action Preventive Action 1 Turret lathe Belt cut 10.30 AM 2.30PM 4 hrs Belt Regular checking Monthly Audits and monitoring the life time of the belt
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
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 –alignment markingகனள கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 rangeஐ காட்டுேைற்காக உள்ள Markingஐ கேைிக்கவும்  Needle எப்சபாழுதும் red marks’க்குள் ைான் இருக்க வேண்டும்  Calibration date stickerஐ கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 ஐ காண்பிப்பைற்காக உள்ள markingsஐ கேைிக்கவும்  Red, yellow and green levelகனள கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 stickerகனள கேைிக்கவும்  Chain rotation direction and eye symbol for inspection area These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 markingகனள கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
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 pipes and the direction of flowஐ கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
An initiative of Hash Management Services LLP A Business Sense Publication For more free resources visit www.businessense.in For any queries / suggestions / requests Call us: +91 91766 13965 or Email us: support@businessense.in MAINTENANCE MODULE IN TAMIL

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Preventive / Autonomous Maintenance - Beginners Guide - Tamil

  • 1.
    MAINTENANCE MODULE IN TAMIL An initiativeof Hash Management Services LLP A Business Sense Publication For more free resources visit www.businessense.in
  • 2.
    Property of HashManagement 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 more efficiently and effectively in the organization  This publication 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 professionals and students who are joining manufacturing organizations  At Business Sense, we help medium scale manufacturing units improve their operational efficiency through consulting engagements 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 day and 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 HashManagement 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 சரியாக வேனல சசய்ேனை ensure சசய்ைிட வேண்டும்  Maintenance function, spares மற்றும் consumablesஐ plan சசய்து ோங்க நடேடிக்னக 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 HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Introduction to Maintenance function கீழ் ே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 keep the 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 ேிடும் Maintenance Preventive Maintenance Autonomous Breakdown Maintenance
  • 5.
    Property of HashManagement 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, production supervisorரிடம் complaint சசய்து Maintenance teamஐ ேரனேப்பார்  Maintenance team ேந்ைவுடன் machineஐ சரி பார்பர்  நினறய companyகளில், Maintenance teamமுடன் Service Level Agreement ஏற்படுத்ைியிருப்பார்கள் ( e.g. maintenance team personnel 30 நிமிடங்களில் machineஐ அனடய வேண்டும் )
  • 6.
    Property of HashManagement 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 ஒவ்சோரு machineக்கும் ஑ருேனர சபாறுப்பாளராக நியமிக்க வேண்டும்
  • 7.
    Property of HashManagement 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 HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. AM சசய்யும் முனறகள் 1. Preparation / ையார் சசய்ைல் 2. Cleaning and Inspection / சுத்ைம் & Inspection சசய்ைல் 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
  • 9.
    Property of HashManagement 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 Step 2 – Initial Cleaning & Inspection / சுத்ைம் & Inspection சசய்ைல்
  • 10.
    Property of HashManagement 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 அறியவும் Knowing the machine & its parts is the primary step
  • 11.
    Property of HashManagement 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 HashManagement 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 WIP materialகனளயும் முழுைாக cover சசய்ய வேண்டும்  Cleaning tools:  Cotton Waste  Tool Box / Trolley  Wire Brushes  Ladder , Screw Driver  Emery Sheet - Medium  Cleaning Agent – Kerosene , Soap oil These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 13.
    Property of HashManagement 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  Missing Abnormalities எங்கு கண்டுபிடிப்பது ?
  • 14.
    Property of HashManagement 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 HashManagement 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 HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality - Missing Nut Missing Nut Nut fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 17.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality - Missing screw Missing Screw Screw fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 18.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – different nut Different Nuts Same type nuts These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 19.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – Painted bolt Bolt head painted! Difficult to remove the bolt in future Paint removed from the bolt head These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 20.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – bend in the bolt Bend in the bolt New bolt and nut fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 21.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – different size washers Different washers used Washers fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 22.
    Property of HashManagement 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 thread Rust in the bolt thread Rust removed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 23.
    Property of HashManagement 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 Contamination These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 24.
    Property of HashManagement 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 reservoir No grease Grease filled These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 25.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – grease level not visible Grease level not visible Grease level visible These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 26.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – excess grease Excess grease Optimal grease These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 27.
    Property of HashManagement 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 / shaft damaged  Belt missing  Tracking  Eccentricity  Play
  • 28.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality - slackness Slackness in belt Slackness removed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 29.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – cooling fan not available Cooling fan – not available Cooling fan fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 30.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – chain guard not available Chain guard – not available Chain Guard - fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 31.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – oil leakage Oil Leakage from the machine Oil Leak fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 32.
    Property of HashManagement 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 HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – gauge not working Gauge damaged / not working Gauge repaired These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 34.
    Property of HashManagement 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 HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – air leakage Air 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 HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – Steam leakage Steam leakage Steam Leakage arrested These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 37.
    Property of HashManagement 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 more heat  Exposed wires  Panel inlet filter block  Panel/junction box open  Screws missing  Dust/dirt  Connections with open wires
  • 38.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – cables not routed properly Cables not routed properly Cables properly fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 39.
    Property of HashManagement 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 ground Cables on the ground Cables laid properly These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 40.
    Property of HashManagement 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 box Holes in the switch box Holes fixed These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 41.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Abnormality – Earthing not done Earthing not done Earthing done These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 42.
    Property of HashManagement 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 HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Template 1 – List of abnormalities VALVES These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 44.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Template 2 – Check lists These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 45.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Template 3 – Audit plan These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 46.
    Property of HashManagement 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 abnormalities Red Tag Status 0 20 40 60 80 Put 64 68 12 14 12 10 16 12 14 Removed 62 64 10 11 10 8 10 14 16 Dec'06 Jan'07 Feb'07 I Feb'07 II Feb'07 III Feb'07 IV Mar'07 I Mar'07 II Mar'07 III Nos These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 47.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Template 5 - Break-down register S.No Machine Break-down reason Breakdown time Machine up time Time taken for repair Spares changed Corrective Action Preventive Action 1 Turret lathe Belt cut 10.30 AM 2.30PM 4 hrs Belt Regular checking Monthly Audits and monitoring the life time of the belt
  • 48.
    Property of HashManagement 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 HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Visual Management  Bolt Alignment –alignment markingகனள கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 50.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Visual Management  Working rangeஐ காட்டுேைற்காக உள்ள Markingஐ கேைிக்கவும்  Needle எப்சபாழுதும் red marks’க்குள் ைான் இருக்க வேண்டும்  Calibration date stickerஐ கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 51.
    Property of HashManagement Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited. Visual Management  Grease level ஐ காண்பிப்பைற்காக உள்ள markingsஐ கேைிக்கவும்  Red, yellow and green levelகனள கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 52.
    Property of HashManagement 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 stickerகனள கேைிக்கவும்  Chain rotation direction and eye symbol for inspection area These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 53.
    Property of HashManagement 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 markingகனள கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 54.
    Property of HashManagement 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 pipes and the direction of flowஐ கேைிக்கவும் These are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures
  • 55.
    An initiative ofHash Management Services LLP A Business Sense Publication For more free resources visit www.businessense.in For any queries / suggestions / requests Call us: +91 91766 13965 or Email us: support@businessense.in MAINTENANCE MODULE IN TAMIL