Total Productive Maintenance Planned Maintenance

Step 1 Evaluate equipment failures

and assess the current situation

• PLANNED MAINTENANCE OBJECTIVE

• EQUIPMENT DETERIORATION

• TYPES OF MAINTENANCE

• PM RESPONSIBILITIES

• ROLE OF PRODUCTION

• ROLE OF MAINTENANCE

• PLANNED MAINTENANCE ACTIVITIES – STEP 1

• DOCUMENTATION EXAMPLES

Early

Managem

ent

Educatio

n a

nd T

rain

ing

Auto

nom

ou

s M

ain

tenance

Focussed Im

pro

vem

ent

Pla

nned M

ain

tenance

TP

M in

Adm

inis

tratio

n

Safe

ty, Health

,

Enviro

nm

enta

l

Quality

Main

tenance

5 S

ZERO EQUIPMENT

FAILURES AND BREAKDOWNS

REDUCE MAINTENANCE

COST BY 20%

ENSURE AVAILABILITY OF SPARES ALL THE

TIME

IMPROVE RELIABILITY AND

MAINTAINABILITY BY 50%

• Schedules maintenance tasks based on predicted and/or measured failure rates • Step 1 duration: 2 – 3 months • Resources – PM pillar committee

Time

Performance

Natural

Deterioration Forced

Deterioration

Limit Line

• Breakdown Maintenance

- Intentional, not unplanned; repairing after breakdowns occur

• Periodic Maintenance

- Time-based Maintenance or Inspection & Repair

• Predictive Maintenance

- Condition Based Maintenance; use of technology for assessing

conditions

• Corrective Maintenance

- Recurrence prevention; improving or modifying equipment to

prevent breakdowns or make maintenance easier

Maintenance ClassificationPreventing

Deterioration

Measuring

Deterioration

Rectifying

Deterioration

Routine Maintenance

Periodic inspectionPeriodic Maintenance

Breakdown Maintenance

Corrective Maintenance

(Maintainability)

Corrective Maintenance

(Reliability)

Minor maintenance

Early Detection of

situation and speedy

countermeasures

Enhancement of

material strength

Reduction of load

Enhancement of

accuracy

Development of

condition monitoring

Oiling

Tightening

Cleaning and

Countermeasures of

defects

Routine inspection of

conditions of use and

deterioration

Roles of the Production Department

Normal Operation

Correct operation

Setup and adjustment

Maintenance Activities to be Performed

Maintenance ClassificationPreventing

Deterioration

Measuring

Deterioration

Rectifying

Deterioration

Sporadic repair

Improvement of

inspection work

Corrective Maintenance

(Maintainability)

Improvement of

maintenance work

Enhancement of

maintenance quality

Breakdown Maintenance

Development of

condition monitoring

Periodic examination

Periodic shutdown

Periodic Maintenance

Trend controlUnscheduled

shutdownPredictive Maintenance

Periodic inspection

Early Detection of

situation and speedy

countermeasures

Corrective Maintenance

(Reliability)

Enhancement of

material strength

Reduction of load

Enhancement of

accuracy

Roles of Maintenance DepartmentMaintenance Activities to be Performed

I ) Activities to Enhance Equipment Availability

Activities to lengthen equipment MTBF

Activities to shorten equipment MTTR

Output Improvement – Zero failures, defects and

accidents

II)

Activitie

s to e

ffic

iently c

onduct

main

tenance

Inp

ut

Re

du

ctio

n

Maintenance Work Planning

Maintenance information management

Maintenance spare parts management

Maintenance cost management

Knowledge and skill development

5. S

tudy o

f P

redic

tive M

ain

tenance

3. C

orr

ective M

ain

tenance a

ctivitie

s

4. M

ain

tenance P

lannin

g a

ctivitie

s

2. P

lanned M

ain

tenance 7

-Ste

p a

ctivitie

s

1. G

uid

ance &

Support

for

Jis

hu H

ozen

IMPLEMENT PREDICTIVE MAINTENANCE AND ROLL OUT TO OTHER EQUIPMENT

EVALUATE THE PLANNED MAINTENANCE SYSTEM

BUILD A PREDICTIVE MAINTENANCE SYSTEM – MAKE CHECKING AND OVERHAULING MORE EFFICIENT

BUILD A PERIODIC MANAGEMENT SYSTEM – TAKE ACTION AGAINST EQUIPMENT WEAKNESSES

BUILD AN INFORMATION MANAGEMENT SYSTEM – SET MAINTENANCE STANDARDS

RESTORE DETERIORATION AND CORRECT WEAKNESSES

EVALUATE EQUIPMENT FAILURE/BREAKDOWN STATUS AND ASSESS THE CURRENT SITUATION

SUPPORT AND GUIDANCE OF JISHU HOZEN ACTIVITY (AM)

STEP 7

STEP 6

STEP 5

STEP 4

STEP 3

STEP 2

STEP 1

STEP 0

Create and

maintain an

equipment ledger

+ negative map

Creation and

implementation of

equipment evaluation standard and ranking

Breakdown Occurrence

Select PM

equipment

Mean time

between failures

(MTBF)

Check sheet

of equipment

current

status

Frequency & Intensity

Rate

Maintenance

Cost

Set goals for the

team with planned

maintenance

Collect data on all

failures/breakdowns

causing production

losses and analyse

Documents:

Equipment logs &

breakdown sheets

Prepare a plan to

carry out the

activities to achieve

the target

1

2 3 4

5 Mean time

to repair

(MTTR)

6

• Equipment logs are raw data for evaluating equipment. Must have design data and show equipment’s operating and maintenance history.

• Collect all data on the failures/breakdowns, which caused production loss and analyse.

Equipment Management Record

Asset No.

Equipment name

Model

Designed by

Date created

Purchased from

Insta

llatio

n lo

catio

n

Purchased date

Purchase price per (R1,000)

Drawing

Substation/line nameDate

Periodic maintenance/modifications and

improvements

Amount per

(R1, 000)

Main failure and repair Amount per

(R1, 000)

Date Location Details (in-house manhour)Date Location Details (in-house manhour)

To decide which equipment receives planned maintenance

• Evaluate each piece of equipment in terms of its effect on safety, quality, operability, maintainability, etc. • Rank equipment (as A, B, or C, for example) and perform maintenance on all units ranked A or B, as well as those for which zero failure is a legal requirement.

• Obtain data on failure numbers, frequencies, MTBFs, etc.

• MTTRs (mean time to repair), maintenance costs, etc.

Examples of planned maintenance goals

Negative Map

Equipment classification

Equipment ledger

MTBF / MTTR

Breakdown occurrence list

Planned maintenance

schedule

Goals for reducing

breakdowns

Component / spare parts list

Equipment ranking sheet

Plant