11. plant maintenance

8/13/2019 11. Plant Maintenance

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Plant Maintenance

Introduction

Impacts of Poor Maintenance

Maintenance Process

Types of Maintenance

Total Productive Maintenance(TPM)

Preventive Maintenance to TPM

Five Pillars of TPM

TPM vs. TQM


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What Is Plant Maintenance?

Plant maintenance-methods, strategies, and practices usedto keep an industrial factory running efficiently.

include anything from regular checks of equipment to makesure they are functioning properly, to cleaning garbage bins

and toilets.

The general aim of plant maintenance is to create aproductive working environment that is also safe for workers.

A maintenance plan can include scheduling times forequipment checkups, trouble-shooting, and general clean-up.

each place of business generally has its own maintenanceplan, tailored to its particularities.


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IMPACT OF POOR MAINTENANCE

1 Reduction of Production capacity

2 Increase of production cost

3

Threat to employee and consumer safety4

Affects customer satisfaction5

Poor product and service quality


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Maintenance Process

Description of the object condition-The most important element in this area is the maintenancenotification. This is used to describe the condition of thetechnical object or to report a malfunction at a technicalobject and request the damage is repaired.

Execution of maintenance tasks-The most important element in this area is the maintenanceorder. This is used to plan the execution of maintenanceactivities in detail, monitor the progress of work and settle thecosts of maintenance tasks.

Completion of maintenance tasks-

The most important element in this area is the maintenancehistory. This is used for long-term saving of the mostimportant maintenance data. This data can be called up forevaluation at any time.


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Types Of Maintenance

1. Breakdown maintenance :

people waits until equipment fails and repair it.

Such a thing could be used when the equipment failure does not significantlyaffect the operation or production or generate any significant loss other than

repair cost.

2. Preventive maintenance ( 1951 ):

daily maintenance ( cleaning, inspection, oiling and re-tightening ).

prevent failure through the periodic inspection or equipment condition

diagnosis

3. Corrective maintenance ( 1957 ) :

It improves equipment and its components so that preventive maintenance

can be carried out reliably.

Equipment with design weakness must be redesigned to improve reliability or

improving maintainability

4. Maintenance prevention ( 1960 ):

It indicates the design of a new equipment. Weakness of current machines are sufficiently studied and are incorporated


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Challenging limits: PM to TPM

Preventive Maintenance

Preventive + Automation

Maintenance

Preventive +Maintenance

Prevention

Productive + Employee

Participation

Total Productive Maintenance

Nippondenso of the Toyota group introducedin Japan in 1960

However with the automation of

Nippondenso, they introduced

Modification for

improving reliability


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Total Productive Maintenance

Maintenance program which involves a newly definedconcept for maintaining plants and equipment.

(Medical Science of machines)

TPM no longer regarded as non-profit activity.

Integral part of the manufacturing process.

Objectives-Avoid wastage in a quickly changing economic environment.

Producing goods without reducing product quality.Reduce cost.

Goods send to the customers must be non defective.


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Five Pillars of TPM


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Comparison of TPM & TQM

Category TPM TQM

Object Equipment ( Input and

cause )

Quality ( Output and

effects )

Mains of Attaining

goals

Employees participation

and it is hardware

oriented

Systematize the

management. It is

software oriented

Target Elimination of losses

and wastes.

Quality for PPM


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Presented By:

Nikhil KulkarniMMS-A

Roll No-34

11. plant maintenance

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