Tpm & Maintenance

MAINTENANCE &TPM

Gopalakrishnan - Role Of Maintenance

WHY MAINTENANCE? • If left unattended, everything will deteriorate – so, maintain • Make the equipments available for production at all times • Prevent the equipment from Forced deterioration • Maintain the condition of the equipment • Improve the performance & reliability of the equipment Gopalakrishnan - Role Of Maintenance

Equipment Condition

What is FORCED DETERIORATION?

Natural Deterioration

Forced Deterioration

Time  Gopalakrishnan - Role Of Maintenance

ROLE OF MAINTENANCE AIM: • Zero Breakdowns • Improve the Quality of maintenance activities APPROACH: • Trap Defects • Progressively eliminate the root causes Gopalakrishnan - Role Of Maintenance

PROGRESS MEASURES • MTBF: Mean time Between Failures • MTTR: Mean Time to Repair / Rectify Problems Understood Counter measures applied ---------------------------------- x --------------------------------- x Problems Known Problems understood

Successful countermeasures --------------------------------------Counter measures applied

Gopalakrishnan - Role Of Maintenance

Classification & Allocation of Maintenance Activities

S e rv ic e R e p a ir

R a p id

A b n o rm a litie s

R e c tify

In s p e c tio n

P e rio d icT e sts

S e tu p&

A d ju s tm e n ts

C le a n in ga s

T re n dT e s ts

N o rm a lo p e ra tio n s P e rio d ic

M a in te n a n c e

P re ve n tiv e

ENG

R E L IA B IL IT Y

OP

M a in te n a n c e

OP

B re a k d o w n

D a ilyM a in te n a n c e

OP

Strengthen Reduce Load Increase Precision

ENG

ENG

M A IN T A IN A B ILIT Y

A c tiv itie s

Im p ro v e m e n t

ALLOCATION Operators / Engineers

M a in te n a n c e

A c tiv itie s

T A R G E T8 5 %

O E E

ACTIVITIES Prevent / Measure / Restore

METHOD

M a in te n a n c e

TARGET

Condition Monitor Test Procedures Standardization

Gopalakrishnan - Role Of Maintenance

ENG

TOTAL PRODUCTIVE MAINTENANCE • • • • • •

PRODUCTION QUALITY COST DEVELOPMENT SAFETY MORALE

Gopalakrishnan - Role Of Maintenance

POLICY Our TPM Policy is to achieve • Higher Overall Equipment Efficiency • With reduced losses and • High reliability of our process. We commit to achieve this policy through • “Zero Breakdowns ”, • “Zero Defects” and • “Zero Accidents”. To achieve this, continuous skill up gradation of employees will be done.

Gopalakrishnan - Role Of Maintenance

PRINCIPLES • Increase OEE • Improve existing Planned Maintenance systems • Routine Asset Care as a part of the job • Increase Skills

TRAIN OTHERS

• Maintenance Prevention

USE

KNOW UNDERSTAND

Gopalakrishnan - Role Of Maintenance

PILLARS • • • • • • • •

FOCUSSED (SELF) IMPROVEMENT AUTONOMOUS MAINTENANCE PLANNED MAINTENANCE QUALITY MAINTENANCE EDUCATION & TRAINING DEVELOPMENT MANAGEMENT SAFETY HEALTH ENVIRONMENT OFFICE TPM Gopalakrishnan - Role Of Maintenance

GOAL OF TPM GOAL: • Increase OEE • Develop optimal relationship between equipment and people METHOD: • Eliminate Six Losses THROUGH: • Measurement Cycle • Condition Cycle • Prevention Cycle Gopalakrishnan - Role Of Maintenance

OVERALL EQUIPMENT EFFECTIVENESS OEE is a product of Availability Rate x Speed Rate x Quality Rate AR = No. of hours m/c run / No. of hours available SR = No. of pcs produced / Standard production QR = No. of pcs Accepted / No. of pcs produced Gopalakrishnan - Role Of Maintenance

SIX BIG LOSSES 1. 2. 3. 4. 5. 6.

BREAKDOWN LOSSES SET-UP & ADJUSTMENT LOSSES IDLING & MINOR STOP LOSSES REDUCED SPEED OPERATION SCRAP & RE-WORK LOSSES START-UP LOSSES

•

7th loss is Blade-loss Gopalakrishnan - Role Of Maintenance

MEASUREMENT CYCLE • COLLECT HISTORY FILE • IDENTIFY THE ORIGINAL SPECIFICATIONS OF THE EQUIPMENT SUPPLIED BY THE MANUFACTURER • COLLECT PERFORMANCE DATA OF THE EQUIPMENT vis-à-vis SPECIFICATIONS • DEFINE REVIEW PERIOD BASED ON THE DATA COLLECTED Gopalakrishnan - Role Of Maintenance

CONDITION CYCLE • CRITICALITY ASSESMENT OF THE EQUIPMENT • CONDITION APPRAISAL FOR THE EQUIPMENT • PLAN REFURBISHING • PREPARE FUTURE CHECK-LIST BASED ON THE OBSERVATIONS Gopalakrishnan - Role Of Maintenance

PROBLEM PREVENTION • STANDARDIZATION OF ACTIVITIES • P-M ANALYSIS (PHENOMENON – MECHANISM ANALYSIS) • SIMPLY, DO

AUTONOMOUS MAINTENANCE Gopalakrishnan - Role Of Maintenance

TPM … • Gives us special lens to see things • Drives us to do more focus on process • Enables us to have control over the equipment’s downtime • Allows us to challenge Status Quo • Forces us to Improve • Helps us to Work Smarter Gopalakrishnan - Role Of Maintenance