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Plant Maintenance
Step 1: Evaluating equipment failures and assessing the current
situation.
Stem 2: Restoration and improvement of deteriorated
equipment
Step 3 : Tentative standard Maintenance Procedure
Step 4: Total inspection of quality function
Step 5: Improvement of inspection and maintenance efficiency
Step 6: Execution of preventive maintenance
Step 7:Horizontal replication
7 steps of planned maintenance7 steps of planned maintenance
Benefits of planned maintenanceBenefits of planned maintenance
• The quality of the part is maintained,
• Increase in production up-time,
• Reduced cost of operations,
• Reduction in the number of machinery required,
• Improving equipment capability and reliability – increasing
the mean-time-between-failures (MTBF),
• Improving equipment maintainability by reducing sporadic
maintenance time – reduction in the mean-time-to repair
(MTTR),
• Establishing/improving predictive maintenance,
• Reduced maintenance costs.
PM Support to JHPM Support to JH
1.Prepare the line diagram
2.Prepare the cleaning Tools
3.Arrange the RED & WHITE Tag
4.Educate the 7 types of abnormality
5.Counter measure for red tags
6.Visuals for step No:1
• Collection of Equipment failure data
• A Negative Map to be prepared
• Equipment to be ranked
– equipment is ranked as A, B or C, based on the severity of the failure and its effect on
safety, quality, production and maintenance. An “A” machine is most critical, causing safety
risks or quality defects during a failure, while a “C” machine will cause no major issues in the
event of a breakdown
• MTTR to be calculated
• MTBF to be calculated
• Goal setting
Step 1: Evaluating equipment failures
and assessing the current situation.
Step 1: Evaluating equipment failures
and assessing the current situation.
Types of MaintenanceTypes of Maintenance
• breakdown maintenance,
• periodic maintenance
– Time based Maintenance(TBM) or Inspection and repairs
• predictive maintenance
– Condition based maintenence
• corrective maintenance
PM Step 2 ProcedurePM Step 2 Procedure

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Plant maintenance

  • 2. Step 1: Evaluating equipment failures and assessing the current situation. Stem 2: Restoration and improvement of deteriorated equipment Step 3 : Tentative standard Maintenance Procedure Step 4: Total inspection of quality function Step 5: Improvement of inspection and maintenance efficiency Step 6: Execution of preventive maintenance Step 7:Horizontal replication 7 steps of planned maintenance7 steps of planned maintenance
  • 3. Benefits of planned maintenanceBenefits of planned maintenance • The quality of the part is maintained, • Increase in production up-time, • Reduced cost of operations, • Reduction in the number of machinery required, • Improving equipment capability and reliability – increasing the mean-time-between-failures (MTBF), • Improving equipment maintainability by reducing sporadic maintenance time – reduction in the mean-time-to repair (MTTR), • Establishing/improving predictive maintenance, • Reduced maintenance costs.
  • 4.
  • 5.
  • 6. PM Support to JHPM Support to JH 1.Prepare the line diagram 2.Prepare the cleaning Tools 3.Arrange the RED & WHITE Tag 4.Educate the 7 types of abnormality 5.Counter measure for red tags 6.Visuals for step No:1
  • 7. • Collection of Equipment failure data • A Negative Map to be prepared • Equipment to be ranked – equipment is ranked as A, B or C, based on the severity of the failure and its effect on safety, quality, production and maintenance. An “A” machine is most critical, causing safety risks or quality defects during a failure, while a “C” machine will cause no major issues in the event of a breakdown • MTTR to be calculated • MTBF to be calculated • Goal setting Step 1: Evaluating equipment failures and assessing the current situation. Step 1: Evaluating equipment failures and assessing the current situation.
  • 8.
  • 9.
  • 10. Types of MaintenanceTypes of Maintenance • breakdown maintenance, • periodic maintenance – Time based Maintenance(TBM) or Inspection and repairs • predictive maintenance – Condition based maintenence • corrective maintenance
  • 11. PM Step 2 ProcedurePM Step 2 Procedure