Equipment maintenance

WELCOME

SUPREME AUTOMECH (INDIA) PVT LTD

PUDHUCHERRY.

EQUIPMENT MAINTENANCEEQUIPMENT MAINTENANCE

MAINTENANCE BY PRODUCTION DEPARTMENT(Jishu Hozen ) PLANNED MAINTENANCE BY MAINTENANCE DEPARTMENT( Keikaku Hozen ) OTHER SUB CONTRACTORS MAINTENANCE ( AMC)

Supreme Automech ( India ) Pvt Ltd Pudhucherry`

PROCESSPROCESS OF EQUIPMENT MAINTENANCE

Five Elements to under stand the Process of Five Elements to under stand the Process of equipment maintenanceequipment maintenance

1.1. What equipment ?What equipment ?2.2. What part of equipment ?What part of equipment ?3.3. What maintenance method ?What maintenance method ?4.4. What standard maintenance procedure should What standard maintenance procedure should

drafted ?drafted ?5.5. What systematic maintenance carry out ?What systematic maintenance carry out ?

Supreme Automech ( India ) Pvt Ltd Pudhucherry

1.What equipment ?

Equipment based on (PQCDS & M) classify (Production , Quality , Cost , Delivery , Safety and Morale ) that & rank your equipment as class

AA,A,B & C

This is not difficult Process


2.What part of equipment ?

This is difficult decision We have decided through Jishu Hozen &

kaikaku Hozen Implementation activities. The critical parts to be identified through

application of techniques.


What maintenance method ?

What Part ? Maintenance method is usually determined by

experience . There is almost no logical or practical methodology

that clearly indicates what maintenance method must be applied on what part of the equipment.

We can control that by using some methodological maintenance.


What method ?

Preventive maintenance 1.Periodic maintenance 2.Predictive maintenance 3.Overhaul

Break down maintenance Corrective maintenance Maintenance prevention


Draft the standard maintenance procedure

The standard maintenance procedure specifies that maintenance method is to be used on what part of the equipment.

5W 1 H – Principle should be used to draft the maintenance standard.


Carry out systematic maintenance

Maintenance tasks must be performed systematically based on the maintenance calendar and standard maintenance procedure.

Jishu Hozen means – Preventive Maintenance.

Keikaku Hozen means – Planned Maintenance.


BREAK DOWN

Why do break down occur ?

Break down occur when applied stress exceeds equipment strength.


CAUSE OF THE BREAK DOWN

A.Neglected deterioration Inadequate compliance with basic

requirements1.Lack of skill such unable to detect

abnormalities caused by stress.2.Not followed the Jishu Hozen such as

cleaning , oiling ,tightening and Inspection.



B.Uncontrolled stressNon compliance with usage requirements is sometimes attributable to production engineers

lack of careful consideration during modification of equipment or conversion of equipment to a different application.

If usage requirements are violated then stress applied to equipment will exceeds the built in stress limits.

( Usage condition such as Power current, RPM, Velocity , Temperature etc., )



Insufficient strength

# Lack of strength can result from design mistakes.

# In this case breakdown occur under normal stress.


Approach to Zero Breakdowns

Five factors affect achieve zero breakdowns1. Non – compliance with usage requirements.

2. Neglected deterioration.

3. Inherent design weaknesses.

4. Lack of skill.

5. Inadequate compliance with basic requirements.


Approach to Zero Breakdowns

Five counter measures to achieve zero failures

1. Adequate compliance with basic requirements.

2. Compliance with usage requirements.

3. Restoration of deteriorated equipment condition.

4. Improvement of design weaknesses.

5. Improvement of operation and maintenance skills.


Jishu-Hozen System( seven steps )

1.Initial cleaning.

2.Countermeasures directed at the source of troubles and difficult to access area.

3.Tentative cleaning and oiling standard procedure.

4.General inspection.

5.Autonomous inspection.

6.Standardization.

7.Autonomous management.


Phase 1- ( Step 1- 3)Attend to basic requirement (Jishu Hozen )

1. Cleaning is Inspection. It starts with getting familiar with equipment by placing tags on troubles detected through cleaning and inspection of every parts of the equipment .

2. Maintenance Personal must carry out the restorative and improvement actions against latent factors of breakdowns.The trouble tags can then removed.

3. Preparing the tentative standard maintenance Procedure.we also must make difficult tasks easier.


Step 4 – 5Activity to upgrade operators skills and equipment

Step 1-3 can only improve visible equipment problem.There are still hidden or invisible problems yet to be identified

and tackled with improvement measures.Before doing general inspection in step 4, Operators will learn

maintenance technology such as hydraulic, pnematics , electricity, lubrication and machines.

By doing General Inspection , all the hidden troubles will be identified and restorative and improvement measures against these can be taken.

As a result ,we will realize our goal of near zero break down.


-- contd.

Throughout the process , operators will have the satisfaction of developing new skills and greater competence.

Based on the knowledge gained from the step 4&5, operators will revise the tentative standard procedure drafted in step 3 and establish a final standard procedure in order to develop the Jishu Hozen system.


TPM

TPM activities can drastically improve equipment condition because TPM promotes the zero breakdown concepts even within small group activities called Jishu Hozen.

TPM encourages everyone’s participation in PM activities .

Top management must keep firmly in mind that without this participation , it will be impossible to achieve dramatic improvements.


Keikaku – hozen( seven steps )

1.Analysis of present status 2.Restoration and improvement of the deteriorated

equipment condition.3.Tentative standard maintenance procedure.4.General inspection of quality function .5.Improvement of inspection and maintenance and

maintenance efficiency.6.Execution of predictive maintenance.7.Horizontal replication.


Keikaku Hozen

Simply to say SORT,CLASSIFY,ANALYZE.the break down for the last 3 years .

Necessity - ?Minimize the cost and maximize the productionPurpose - ?To ensure the equipment condition at their best with the

minimum maintenance cost, enabling equipment to function at an optimal level whenever operation required

Way of thinking - ?Decide what maintenance method is to be applied on what

part of what equipment and to carry out maintenance systematically.


Main activities and aims.

1.Support activity for the production department.2.Zero break down activity.3.Establish maintenance planning maintenance.4.Maintanence information management system

development.5.Spare parts control6.Predictive maintenance system development .7.Lubrication management.8.Maintanence skill education.


Method of keikaku hozen

1.PM ( Preventive maintenance )

Classified in three methods .

A . Periodic maintenance

It is time based maintenance ( TBM )

It is choosed based on the parameter

( production volume or days)

It does not take manpower or time for inspection . But repair cost high because of over - maintenance.

Supreme Automach ( India ) Pvt Ltd Pudhucherry

B. Predictive maintenance – ( Condition based maintenance - CBM)

Monitor and analyze the deterioration data regularly and constantly .

Repair if the deterioration parameter reaches a pre-determined critical value.

CBM can prevent over – maintenance ,which is a problem with TBM.

Equipment diagnosis and monitoring systems can be costly.


C.Over haul : Inspection Repair ( IR )

# Disassemble and inspect the equipment regularly and judge its condition . Replace defective parts if found.

# This I R can be placed between CBM and TBM .

# Production schedules need to be adjusted. There needs to be spare equipment.


2.Break down Maintenance ( BM)

# No regular Inspection and replacement are carried out .

# Equipment is restored after breakdown.

# Apply this if fixing after failure is more economical.

# extracts maximum service life . Most economical if breakdown does not affect other equipment

# If there are numerous pieces of equipment , there may be numerous breakdown which can affect production quantity and quality.


3.Corrective Maintenance ( CM )

# Corrective maintenance Involves equipment improvement that result in maintainability and reliability improvements.

# Prevention of breakdowns recurrence ,service –life extension, maintenance time reduction, productivity improvements , etc.


4.Maintenance Prevention ( MP )

MP activities can be proactively implemented not only during the new equipment design stage but also in existing equipment modification.


APPROACH OF ACHIEVING ZERO BREAKDOWNS

THE IDEA OF ACHIEVING ZERO BREAKDOWNS CONSISTS OF ‘MAINTANENCE ‘ AND ‘ PREVENTION ‘ .

As discussed earlier , there are many approaches to achieving zero breakdowns.


ZERO BREAKDOWN

Identify accelerated deterioration factors and carry out restoration and improvement of equipment condition.

Extend inherent service – life of the equipment .

Research the natural deterioration pattern. Search of deterioration parameter. Implement predictive maintenance.


GOOD WISHES & THANK YOU!!!

Equipment maintenance

Engineering

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