Planned Maintenance

Technique

DOWNTIME

TRAINING OVERVIEW

TPM PROCESS
PREPARATION

ANNOUNCEMENT
LAUNCH
CREATE ORGANIZATIONAL STRUCTURE
ESTABLISH POLICIES AND GOALS
FORM A MASTER PLAN

PRELIMINARY IMPLEMENTATION: KICK OFF

TPM PROCESS
IMPLEMENTATION

IMPROVE CRITICAL EQUIPMENT EFFECTIVENESS

SETUP AND IMPLEMENT AUTONOMOUS MAINTENANCE
ESTABLISH PLANNED MAINTENANCE SYSTEM
PROVIDE TRAINING
DEVELOP EARLY EQUIPMENT MANAGEMENT

STABILIZE
RE-MEASURE
START OVER - WORK TOWARD IDEAL STATE

PLANNED
MAINTENANCE
THIS PROCESS:
A PLANT TECHNIQUE
IMPROVEMENT METHODOLOGY
- IMPROVE MANAGEMENT OF PLANT ASSETS

ENABLES CONTINUOUS & RAPID IMPROVEMENT

- SPEED OF THE RABBIT, PERSEVERANCE
OFTHE TORTOISE

Employee Involvement and

Measurements
REQUIRES EMPLOYEE INVOLVEMENT &
EMPOWERMENT
- MY PLANT THEME
- INCREASE IN WORKERS ROLES
- FAILURE DOES NOT DEPEND ON A UNION OR
UNION PLANT

NON-

USES A CLOSED LOOP MEASUREMENT OF

RESULTS
- ELIMINATE INEFFECTIVE PERFORMANCE
- QUALITY, COST, PRODUCTIVITY DELIVERY,

MEASURES
SAFETY

BENEFITS
MAINTAIN THE QUALITY OF THE PRODUCT
INCREASE PRODUCTION UP-TIME
REDUCE COSTS OF OPERATIONS
REDUCE AMOUNT AND COMPLEXITY OF
MACHINERY REQUIRED
INSURE EQUIPMENT CAPABILITY

TRAINING

WORLD CLASS ASSEMBLY

AND MANUFACTURING
REQUIRES
WORLD CLASS MAINTENANCE
UP-TIME

QUALITY

SAFETY

PEOPLE INVOLVEMENT

WORLD CLASS MAINTENANCE =

PLANNED MAINTENANCE PREVENTION TOTAL COST

PREVENTIVE METHODS & SYSTEMS

PREDICTIVE TECHNOLOGIES

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE
TRAINING INTRODUCTIONS
NAME
CURRENT POSITION
ADMINISTRATIVE DETAILS
RESTROOMS
MESSAGES
SAFETY ISSUES
LUNCH & BREAK

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE
MEETING AGENDA

INTRODUCTION & ADMINISTRATIVE DETAILS

WHY WE ARE HERE
TRAINING PROCESS
MAINTENANCE VIDEO (Optional)
WASTE TRAINING
ANALYZE SUPPLIER VIDEO (Optional)
DEFINE CURRENT STATE

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE
MEETING AGENDA

IDENTIFY OPPORTUNITIES
DEVELOP NEW PROCESS
IMPLEMENT IMMEDIATE IDEAS
EVALUATE NEW PROCESS
VIDEOTAPE (Optional) & MEASURE

COMPLETE SUMMARY OF RESULTS

COMPLETE ACTION PLANS
SHORT & LONG TERM

WRAP UP

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE
OPERATING GUIDELINES

BE ON TIME
EVERYONE PARTICIPATES/ EQUAL VOICE
ONE SPEAKER AT A TIME
HANDLE OTHER BUSINESS ON BREAKS
MAKE PAGERS SILENT
FUNCTION AS A TEAM
SPEAK LOUDLY AND CLEARLY
NO ONE LEAVES UNTIL THE NEW PROCESS
WORKS!
HAVE FUN

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE
WHAT IS THE EFFECT OF POOR
MAINTENANCE ACTIVITIES?
INVENTORY
LEAD TIME
QUALITY
COST
CAPACITY
NEW BUSINESS

>
>
>
>
>
>

MORE THAN IS NEEDED

SLOWER THAN NECESSARY
NOT AS GOOD AS IT COULD BE
HIGHER THAN YOUR COMPETITORS
LOWER THAN IT COULD BE
MAY NOT BE ABLE TO CAPTURE

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE -- Safety
Safety

SAFETY WILL NOT

BE COMPROMISED !!!

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE -- Definition
Definition
DEFINITION
System of Activities in Which All Employees
Work to Improve Up-Time, Quality of Output and
Reduce Maintenance Costs Through the
Continuous Improvement of Equipment
Operation. Includes Preventative and
Predictive Scheduled Maintenance Programs.

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE -- Goal
Goal

THE GOAL IS TO ACHIEVE THE

ABSOLUTE MINIMUM AMOUNT OF
TIME NEEDED FOR EFFECTIVE
MAINTENANCE.

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE -- Waste
Waste Elimination
Elimination
WASTE ELIMINATION
ANYTHING THAT DOES NOT ADD
VALUE TO THE MAINTENANCE
ACTIVITY.
WORKPLACE ORGANIZATION
VISUAL CONTROLS

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE -- More
More Waste
Waste
WASTE OF:
INVENTORY
OVERPRODUCTION
CORRECTION
MATERIAL & INFORMATION
MOVEMENT
PROCESSING
WAITING
MOTION

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE -- Activity
Activity Model
Model
MAINTENANCE ACTIVITY MODEL
NON-DISCRETIONARY

DISCRETIONARY
- REARRANGEMENTS
- MODIFICATIONS
- CONSTRUCTION

PROACTIVE

REACTIVE

(SCHEDULED)

(UNSCHEDULED)

- BREAKDOWNS
- REPAIR
- EMERGENCIES

PREDICTIVE

PREVENTIVE

- VIBRATION ANALYSIS
- INFRARED
- FIBER OPTICS
- ULTRASONIC
- MACHINE HISTORIES

- VISUAL INSPECTION
- TIME SCHEDULING
- HOURS OF USAGE
- MINOR REPAIR

Types
Types of
of Maintenance
Maintenance
FOUR TYPES OF MAINTENANCE
REACTIVE

PREDICTIVE

PREVENTIVE

PREVENTION

Reactive
Reactive Maintenance
Maintenance
SYSTEM:

RESPONSE TO EQUIPMENT MALFUNCTIONS

CHARACTERISTICS:
- INEFFICIENT MAINTENANCE DEPARTMENT
- UNPREDICTABLE EQUIPMENT OPERATION
- ALL MAINTENANCE WORK UNPLANNED
EXAMPLE: LIGHT BULB REPLACEMENT

RESULTS:

STEADY DEGRADATION OF EQUIPMENT

PERFORMANCE

MAINTENANCE DEPARTMENT RESPONSIBILITY:

- RESPOND TO EMERGENCIES
- GET PRODUCTION BACK ON LINE

Preventive
Preventive Maintenance
Maintenance
SYSTEM:
- PERIODIC ADJUSTMENTS & CHECKS
- PERIODIC REPLACEMENT OF WORN PARTS
- PERIODIC OVERHAUL

CHARACTERISTICS:
- MORE PREDICTABLE
- MORE EFFICIENT
EXAMPLE: CHANGING OIL & FILTERS

RESULTS:

MAINTAIN LEVEL OF EQUIPMENT

MAINTENANCE DEPARTMENT RESPONSIBILITY:

- CHECKING, REPLACING & OVERHAULING
- PERFORM CHECKS DURING MAINTENANCE

Predictive
Predictive Maintenance
Maintenance

SYSTEM:

PERIODIC MEASUREMENT & TRENDING OF

EQUIPMENT PROCESS

CHARACTERISTICS:
- PREDICTABLE MAINTENANCE REQUIREMENTS
- PLANNED & SCHEDULED EQUIPMENT REPAIRS
EXAMPLE: VIBRATION ANALYSIS

RESULTS:

MAINTAIN EQUIPMENT PERFORMANCE WITH

MINIMAL DISRUPTION TO PRODUCTION

MAINTENANCE DEPARTMENT RESPONSIBILITY:

- LOG EQUIPMENT REPAIRS
- TREND DATA
- PREDICT EQUIPMENT REPAIR CYCLES

Prevention
Prevention Maintenance
Maintenance

SYSTEM:

EQUIPMENT DESIGN IS BASED ON MINIMAL

MAINTENANCE REQUIREMENTS

CHARACTERISTICS:
- CLOSE RELATIONSHIP WITH EQUIPMENT SUPPLIERS
EXAMPLE: SEALED BEARINGS IN SMALL ELECTRONIC MOTORS

RESULTS:

CONTINUALLY IMPROVING EQUIPMENT

MAINTENANCE DEPARTMENT RESPONSIBILITY:

- INPUT TO EQUIPMENT DESIGN
- MINIMIZE & ELIMINATE MAINTENANCE
REQUIREMENTS

The
The Six
Six Big
Big Losses
Losses

DOWNTIME:
1.
2.

BREAKDOWNS DUE TO EQUIPMENT FAILURE

SET-UP AND ADJUSTMENT

SPEED LOSSES:
3.
4.

IDLING AND MINOR STOPPAGES

REDUCED SPEED

5.
6.

SCRAP AND QUALITY DEFECTS

REDUCED YIELD

DEFECTS:

Breakdown
Breakdown Causes
Causes

BASIC CONDITIONS NEGLECTED

INADEQUATE SKILLS
OPERATING STANDARDS NOT FOLLOWED
DETERIORATION UNCHECKED
INHERENT DESIGN WEAKNESS

Idling
Idling and
and Minor
Minor Stoppages
Stoppages

CHARACTERISTICS:
-

EASY TO RESTORE - THEREFORE - EASILY IGNORED

CONDITIONS OF OCCURRENCE VARY
LOCATION CHANGES CONSTANTLY
SCOPE OF LOSS (COST) UNCLEAR

STRATEGIES TO REDUCE:
-

CORRECT SLIGHT DEFECTS IN PARTS AND JIGS

ENSURE BASIC EQUIPMENT CONDITIONS ARE MAINTAINED
REVIEW BASIC OPERATIONS
CONDUCT PHYSICAL ANALYSIS
ADOPT AN ANALYTICAL APPROACH

Reduced
Reduced Speed
Speed (Speed
(Speed Loss)
Loss)
WHAT IS A SPEED LOSS?
THE DIFFERENCE BETWEEN DESIGNED SPEED AND ACTUAL SPEED.

CHARACTERISTICS:
- VAGUE EQUIPMENT SPECIFICATIONS
- SPECIFIED SPEEDS ARE ATTAINABLE, BUT NOT ACHIEVED
- INADEQUATE INVESTIGATION OF PROBLEMS
UNRESOLVED DEFECT DO TO INSUFFICIENT CORRECTION
IN ENGINEERING STAGE

- DEFECTS IN EQUIPMENT MECHANISMS OR SYSTEMS

- INADEQUATE DAILY MAINTENANCE

STRATEGIES:
- ACHIEVE AND INCREASE STANDARD SPEED FOR EACH
PRODUCT
- ACHIEVE AND SURPASS DESIGN SPEED

Defects
Defects

WHAT IS A DEFECT?
A DEFECT IS AN ERROR THAT WAS NOT STOPPED AT POINT OF
OCCURRENCE.

HOW CAN A DEFECT BE PREVENTED?

DEFECT PREVENTION CAN BE ACCOMPLISHED THROUGH THE
USE OF ERROR PROOFING TECHNIQUES AND STRATEGIES.

CHARACTERISTICS:
- IMPROVEMENT EFFORTS HAVE BEEN UNSUCCESSFUL
- PROBLEM IS APPROACHED IN THE WRONG WAY
- CHRONIC DEFECT SOLUTIONS LIMITED TO SPECIFIC FIELDS

Defects
Defects -- Strategies
Strategies
STRATEGIES:
OBSERVE AND STUDY
- ACTUAL FLOOR OPERATIONS
- SETUP ADJUSTMENT OPERATIONS
- THE EQUIPMENT ITSELF
BREAKTHROUGH THINKING
- CHANGE THE STATUS QUO
- RESPONSIBILITY ON THE PART OF ALL EMPLOYEES

STABILIZE BASIC FACTORS

- PROCESS PRINCIPLES
-

MECHANISMS
OPERATION & ADJUSTMENT
PRECISION OF EQUIPMENT, JIGS AND TOOLS
WORK METHODS

PERFORM COMPARATIVE STUDIES

Autonomous Maintenance
INITIAL BARRIERS TO AUTONOMOUS MAINTENANCE
- PERCEPTION OF WORK RULE VIOLATIONS
- MANAGEMENT'S' UNWILLINGNESS TO INVEST
- PERCEPTION OF HEAD COUNT REDUCTION
- BELIEF THAT CLEANING EQUIPMENT IS
USELESS EXERCISE
- PERCEPTION THAT HOUSEKEEPING IS FOR
DIGNITARY VISITS

BARRIERS

77 Levels
Levels of
of Autonomous
Autonomous Maintenance
Maintenance

SEVEN LEVELS OF AUTONOMOUS MAINTENANCE

1.

INITIAL CLEANING

2.

PREVENTIVE CLEANING MEASURE

3.

DEVELOPMENT OF LUBRICATION &

CLEANING STANDARDS

4.

GENERAL INSPECTION

5.

AUTONOMOUS INSPECTION

6.

PROCESS DISCIPLINE

7.

INDEPENDENT AUTONOMOUS
MAINTENANCE

BARRIERS

Autonomous
Autonomous Maintenance
Maintenance

INITIAL CLEANING
ACTIVITY:
THOROUGHLY REMOVE DUST AND CONTAMINANTS
FROM EQUIPMENT
- INCLUDE DISCARD OF OLD EQUIPMENT AND PARTS

GOALS:
PREVENT DETERIORATION
ELIMINATE DUST AND DIRT
IMPROVE QUALITY OF INSPECTION AND REPAIRS
REDUCE FUTURE TIME REQUIREMENTS
DISCOVER AND TREAT HIDDEN DEFECTS

Autonomous
Autonomous Maintenance
Maintenance -- Cleaning
Cleaning

PREVENTIVE CLEANING MEASURES

ACTIVITY:
ELIMINATE SOURCES OF DUST AND DIRT
IMPROVE ACCESSIBILITY
REDUCE LUBE AND CLEANING TIME

GOALS:
INCREASE RELIABILITY OF EQUIPMENT
IMPROVE MAINTAINABILITY OF CLEANING & LUBE

01/03/96

Lubrication
Lubrication and
and Cleaning
Cleaning Standards
Standards
AUTONOMOUS MAINTENANCE-CONTD
DEVELOPMENT OF LUBRICATION AND
CLEANING STANDARDS
ACTIVITY:
SET CLEAR STANDARDS
-

CLEANING
LUBRICATION
BOLTING

GOALS:
MAINTAIN EQUIPMENT CONDITIONS

General
General Inspection
Inspection
AUTONOMOUS MAINTENANCE-CONTD
GENERAL INSPECTION
ACTIVITY:
CONDUCT TRAINING ON REQUIRED SKILLS
FIND AND CORRECT MINOR DEFECTS
MODIFY EQUIPMENT TO AID INSPECTION

GOALS:
VISUALLY INSPECT MAJOR PARTS
RESTORE DETERIORATION
ENHANCE RELIABILITY
FACILITATE INSPECTION TROUGH INNOVATIVE METHODS

Autonomous
Autonomous Inspection
Inspection
AUTONOMOUS MAINTENANCE-CONTD
ACTIVITY:
DEVELOP AND USE AUTONOMOUS CHECKLIST
STANDARDIZE
- CLEANING, LUBRICATION AND INSPECTION STANDARDS

GOALS:
MAINTAIN OPTIMAL EQUIPMENT CONDITIONS
USE VISUAL CONTROL SYSTEMS
REVIEW EQUIPMENT AND HUMAN FACTORS
- FIX PROBLEMS AND SAFETY FACTORS -

IMPLEMENT IMPROVEMENTS FOR EASIER OPERATIONS

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE
AUTONOMOUS MAINTENANCE-CONTD
PROCESS DISCIPLINE
ACTIVITY:
IMPROVE WORK EFFECTIVENESS, PRODUCT QUALITY
AND SAFETY THROUGH WORKPLACE ORGANIZATION
AND HOUSEKEEPING
REDUCE SET-UP AND ADJUSTMENT TIME
ELIMINATE WORK IN PROCESS
INSTITUTE MATERIAL HANDLING STANDARDS
COLLECT AND RECORD AND USE DATA

CONTROL STANDARDS FOR:

RAW MATERIAL, WIP, PRODUCTS, SPARE PARTS, DIES,
JIGS AND TOOLS

Process
Process Discipline
Discipline
AUTONOMOUS MAINTENANCE-CONTD
GOALS:
REVIEW AND IMPROVE PLANT LAYOUT
STANDARDIZE CONTROLS
IMPLEMENT VISUAL CONTROL SYSTEMS

PLANNED
PLANNED MAINTENANCE
MAINTENANCE
TECHNIQUE
TECHNIQUE
AUTONOMOUS MAINTENANCE-CONTD
INDEPENDENT AUTONOMOUS MAINTENANCE
ACTIVITY:
DEVELOP COMPANY GOALS
ENGAGE IN CONTINUOUS IMPROVEMENT ACTIVITIES
IMPROVE EQUIPMENT

GOALS:
COLLECT AND ANALYZE DATA
IMPROVE EQUIPMENT TO:

- INCREASE RELIABILITY
- SIMPLIFY OPERATION

PINPOINT WEAKNESSES IN EQUIPMENT

IMPLEMENT IMPROVEMENT PLANS TO:
- LENGTHEN EQUIPMENT LIFESPAN & INSPECTION CYCLES

COUNTERMEASURES FOR BREAKDOWNS

The Five Types of Breakdown Countermeasures

Maintain
Basic
Conditions

Adhere to
Operating
Procedures

Discover
& Predict
Deterioration

Improve Operation Skills

Correct
Defects
in Design

Restore
Deterioration

Establish
Repair
Methods

Prevent
Human
Errors

Prevent
Operation
Errors

Improve Maintenance Skills

Prevent
Repair
Errors

TOTAL MAINTENANCE IN
LEAN MANUFACTURING CONCEPT
Preventive
Medicine

Daily
Prevention

Health
Checkups
(Diagnosis)

Failure
Rate

Early
Treatment

Prevents
Deterioration

Measures
Deterioration

Repairs
Deterioration

Daily Maintenance
(Lubricate, Clean,
Adjust, Inspect)

Inspection
(Diagnosis)

Make Preventive
Repairs (Advance
Replacements)

Preventive
Maintenance

Startup
Failure
Period

Chance
Failure
Period

Wear-Out
Failure
Period

Useful
Life

Reduction of
Failure Through
Maintenance

Specified
Breakdown
Rate

CATEGORY

STARTUP
FAILURE

CHANCE
FAILURE

WEAR-OUT
FAILURE

CAUSE

Decision/
Manufacturing
Errors

Operational
Errors

Wear-Out

Trial runs at
Acceptance &
Start-up Control

Proper
Operation

Preventative &
Maintainability
Improvement

COUNTER
MEASURES

Maintenance Prevention