Conference on

Best Practices in Maintenance Management
Session Role Of Planned Maintenance In Implementation Of TPM
Speaker: Dinkar Joshi Designation: Sr Manager ( HOD Maintenance) Organization: Endurance Technologies Pvt. Ltd., Aurangabad

May 11th & 12th 2010, Pune India

Role Of Planned Maintenance In Implementation Of TPM

May 11, 2010.

“Best Practices in Maintenance Management” Pune

2

What is TPM?
Total Profit Management …………………Company Survives

Total Production Management ………………… ISO, TQM, JIT, Re-Engineering

Total Perfect Manufacturing
…………………. Loss Elimination

Total Productive Maintenance and Management
May 11, 2010. “Best Practices in Maintenance Management” Pune 3

TPM Principles

By implementing TPM, we get a proper image of “manufacturing product” in the age of automation and microelectronics, there by contributing to the prosperity of enterprises and the happiness of

mankind.

May 11, 2010.

“Best Practices in Maintenance Management” Pune

4

Through TPM ……
1. We pursue efficient production systems and accomplish the highest
customer satisfaction for quality, cost and delivery term.

2. We accomplish zero-disasters & accidents, zero-defects, and zero
breakdowns to build safe and cheerful workshops.

3.

We accomplish zero-disasters and zero-pollution to make life safer and more pleasant, not only for employees, but also for local residents.

4. We eliminate all losses in the resources and energy to conserve the Earth’s environment.
“Best Practices in Maintenance Management” Pune

May 11, 2010.

5

May 11. “Best Practices in Maintenance Management” Pune 6 .Basic Concept Of TPM  CHANGE THE MACHINE.  CHANGE THE MAN. 2010.

ZERO Operate in a manner. By Keeping Target of Defects . so that there are no customer complaints. “Best Practices in Maintenance Management” Pune 7 .TPM Targets Obtain Minimum 90% OEE ( Overall Equipment Effectiveness ) By Keeping Target For All Losses .ZERO May 11. 2010.

2010.ZERO Achieve 100% success in delivering the goods as required by the customer.TPM Targets Reduce the manufacturing cost By Keeping target of Losses . 8 . By Targeting Losses “Best Practices in Maintenance Management” Pune -ZERO May 11.

ZERO Increase the suggestions by 3 times. Target For Accidents . 2010. Develop Multi-skilled and flexible workers. May 11. “Best Practices in Maintenance Management” Pune 9 .TPM Targets Maintain a accident free environment.

2010. “Best Practices in Maintenance Management” Pune 10 .TPM Targets Breakdown Accidents ZERO Defect Losses May 11.

“Best Practices in Maintenance Management” Pune 11 . 2010.What Is Zero…….   ZERO MEANS ONLY ZERO !!! ZERO HAS NO TOLERANCE ZERO DEFECT ZERO BREAKDOWN ZERO ACCIDENT    May 11.

Importance Of Zero……. May 11. 2010. • Just Imagine that if 1% of all the heart surgeries failed. “Best Practices in Maintenance Management” Pune 12 . • Just Imagine that if 1% of all the flights crashed. • Just Imagine that if 1% of the buildings collapsed soon after construction.

Health & Environment “Best Practices in Maintenance Management” Pune 13 TPM Pillar Structure .May 11. 2010. Individual Improvement Planned Maintenance Development management Education & Training TPM 5 S is The Base Of TPM Autonomous Maintenance Quality Maintenance TPM in Offices Safety.

Seiri Seiton Seiso Seiketsu Shitsuke Organization Tidiness Cleaning Standardization Discipline Sort Systematic Sweep Standardize Self .Discipline “Best Practices in Maintenance Management” Pune 14 .Concepts Of 5S Japanese English Translation Equivalent 'S' term Term 1S 2S 3S 4S 5S May 11. 2010.

Example Of 2S 1S. “Best Practices in Maintenance Management” Pune 15 . 2010. 2S EVERYTHING ON ITS OWN PLACE BEFORE AFTER NO FIX LOCATION FIX LOCATION BENEFIT : REDUCE SEARCHING TIME. REDUCE FATIGUE May 11.PLASE FOR EVERYTHING.

REDUCE FATIGUE May 11. 2010. 2S EVERYTHING ON ITS OWN PLACE BEFORE AFTER NO FIX LOCATION FIX LOCATION BENEFIT : REDUCE SEARCHING TIME.Example Of 2S 1S.PLASE FOR EVERYTHING. “Best Practices in Maintenance Management” Pune 16 .

“Best Practices in Maintenance Management” Pune 17 . 2010.Example Of 2S 1S.PLASE FOR EVERYTHING. 2S EVERYTHING ON ITS OWN PLACE BEFORE AFTER NO FIX LOCATION FIX LOCATION BENEFIT : REDUCE SEARCHING TIME. REDUCE FATIGUE May 11.

2010. Loss Elimination • Implementing Kobetsu Kaizen Themes.Key Activities • Reviewing Business Objective • Loss Structure • Target setting for achieving Business Objective • KPI’s for measuring in KRA. 18 . Improved System with Improved Maintainability Support PM Pillar “Best Practices in Maintenance Management” Pune May 11.

• Defect Analysis using different tools.Key Activities • Listing / Stratification of Defects. Defect Elimination • QM Matrix • CBM of Q Components. • Sustenance and Reliability Enhancement. “Best Practices in Maintenance Management” Pune 19 . • Elimination of Customer Complaint Support by PM Pillar May 11. 2010. • Implementing Defect Elimination Projects. • CBM of Q Components for easy Inspection • Reduction of Inspection / Sampling Cost. • QA / 4M / QM / Q Components. • Q Components.

Key Activities • Practicing CLIRT activities during all steps. • Practicing tentative standards • Monitoring & recording abnormalities using 5 senses deterioration I Do. I Check. I Maintain • Countermeasure against source of contamination • Reduction in CLIRT time Support by PM Pillar May 11. “Best Practices in Maintenance Management” Pune 20 . 2010.

2010. Zero Accident / Health hazard • Reducing Environmental Impacts Improved & Safe Working Atmosphere May 11.. Support by PM Pillar 21 “Best Practices in Maintenance Management” Pune . • Safety patrol for Identifying Unsafe Condition & Acts.Key Activities • Prevention of Occurrence & Recurrence of accidents. • Health Hazard Elimination using tools such as mapping etc.

2010.Key Activities • Skill Assessment • Identifying Training Needs for achieving business objective. • Review the skill level and if not okay retrain. Upgraded Skill level for achieving Business Objective May 11. “Best Practices in Maintenance Management” Pune Skill / Knowledge Improvement Support by PM Pillar 22 . • Imparting Training / OJT / External happenings in the market. • Continuous Monitoring.

May 11. Support by PM Pillar Cost Awareness / Cost Effective Programs.Key Activities • Elimination of Administrative Losses by eliminating Waste activity & Reducing Non value added activity • Reducing the manufacturing Cost OTPM Loss Elimination through cost loss approach with KK pillar. 2010. “Best Practices in Maintenance Management” Pune 23 .

“Best Practices in Maintenance Management” Pune 24 . zero accident by implementation of MP on new machines/ equipements Trouble free new equipment from day one Support by PM Pillar May 11. 2010.Key Activities • Collection & utilization of feed back Measuring needs for ease of manufacturing Developing new product with minimum losses Zero breakdown. zero defect.

“Best Practices in Maintenance Management” Pune 25 .Key Activities • Activities to prevent deterioration • Activities to measure deterioration • Restore deterioration . •Input to DM for MP Kaizens May 11. •Support to JH Zero Failure •Skill enhancement of Maintenance staff. 2010.

2010. 2. May 11.Planned Maintenance Aim : Enhance maintenance efficiency through 1. Reducing input by activities to make equipment maintenance efficient. “Best Practices in Maintenance Management” Pune 26 . Accomplishing zero failures and zero defects by activities to enhance maintenance technology and skills. Purpose : Functions of equipment can be demonstrated satisfactorily whenever equipment needs them at minimum cost. to expand equipment MTBF and to shorten equipment MTTR.

09 Jan. “Best Practices in Maintenance Management” Pune 27 . In Lac Nos. Nos Hrs/emp/month Z 0 B V May 11.. 2010./Piece Rs /piece X Y C Rs.Targets Current Status Activity Breakdown hrs. Hrs Nos.10 Feb. of Phenomenon UOM BM Dec.Planned Maintenance . No.10 0 0 0 End Target P Breakdown Occurrences Defect due to PM Q Maintenance Cost Energy Cost Electricity / Fuel / Water Spare part Inventory Cost S Accident due to weak PM Kaizens M Training No of kaizen / employee / month PM Training Rs.

2010.Basic Philosophy of Zero Failure • Men make equipment fail.” May 11. “Best Practices in Maintenance Management” Pune 28 . • Conventional view of “all equipment can fail” should be changed to “don’t let equipment fail.” “failures can be reduced to zero. • Equipment can be set for zero-failures provided the thinking of men change.

cracks • Temperature.Rules for Zero Failure  Discover latent defects to prevent failures. adhesion of raw materials. sound and other errors Latent defects May 11. leaks • Corrosion. Soiling. flaws. “Best Practices in Maintenance Management” Pune 29 . Failure • Dust. vibration. deformation. looseness. 2010. “Failure” is only the tip of the iceberg. • Abrasion. backlash.

Failure Analysis to identify Root Cause Counter Measures and Kaizens Sustenance Activities Periodic Maintenance (TBM) Predictive Maintenance (CBM) Lubrication & Spare Parts Management Enhancement of Knowledge & Skill of Maintenance Operators “Best Practices in Maintenance Management” Pune May 11. 30 . 2010.PM Pillar Methodology Study of past Equipment History Ranking of Equipment Support to JH Preparation of JH3 tent. and TBM Equip. Stds.

“Best Practices in Maintenance Management” Pune .Equipment Ranking A : High Priority Equipment or M/C Most Critical m/c B : Medium Priority Equipment or M/C C : Least Priority Equipment or M/C Ranking of m/c sub parts are done in the same way. May 11. 2010.

o h t xe t o s a r f e t e ok n ir n e t ( en is . 5 0 : 4 Ud r R. e n im o e a ? MT ) 4 2 1 Sf t ae y 9 T wa e t n d e af iluea f c th wr e v o mn? 5 4 2 1 . “Best Practices in Maintenance Management” Pune . 2010. a te r d c n tc 4 2 1 6 Hw ill th po e sr no th e u mn a f c th . u t t ) A P io it Rn e : >3 p ins B S mr n e :2 ~ 0p ins C LatS n ic n ):< 9p i t : r r y a kd 0 o t : e i a kd 0 3 o t ( e s ig if a t 1 ons May 11. o h t xe d ill alue f e t th r r c s e ? 4 2 1 5 4 2 1 Qa y u lit 5 Vlu o mn lys r plo s s . o h h e e ic tio ? ( r p r no po u tso as ila ty epo u e b th Po otio f r d c f im r p r d c d y e e u mn q ip e t) 4 T wa e t n w af i r e f c o e po e s s . S mwa o e ht : 2 Nt S n ic n : 1 o ig if a tly Oe R. r q e c f alue e m f o t f o th e a s 4 2 1 eCs ot 8 Ma T eT Rp ir ( T R .5a h Ud r2 0 0 : 1 Ud r1L k ne 50 ne a h :1 Dc iv ly e is e :5 4 . o w e r c s u n is q ip e t f e t e 5 4 2 1 Qa o th f is e po u t? u lity f e in h d r d c Mine a c 7 Fe u n yo f i r sint r so c s o mn lyr p ir ? a t n n . a e f o th c a s e ( un dr b e . ws dc th ws dpo u tio e ) B r e u b r a te lo . s e e a k p q ip e t? 5 4 2 1 IE TM 1 Hw f nisth E u mn u e ? . 3 0 : 1 vr s 0 0 ne s 00 R.5 a h 2 0 0~5 0 0 : 2 1L k ~2 l k : 2 50 00 a h . f ms d s ec lik o e u e . u k s o a y a h us Aa bea o e pa ts: 4 v ila l t th r l n C v r db s c : 2 o e e y to k Bc u E u mn e is : 1 a k p q ip e t x ts 1 0~ 5 : 4 0 7% 3 ~7 %: 2 5 5 0~3 % : 1 5 Af c th e tir p n : 5 f e ts e n e la t Af c o e po e s s: 4 f e ts th r r c s e Olya f c toth m : 1 n f e ts is / c ( a te po u tio ) Ws d r d c n ( a te C th Ws d lo ) Oe R. 3 0 ~5 0 : 2 s 00 00 Oe 3Hus : 4 Ud r1Hu vr o r ne o r :1 1~3Hus or :2 Cnb lif the te in : 5 a e e ra n g S p wr : 4 to s ok N S n ic n e f c: 1 o ig if a t f e t 3 Hw ig isth d d a n . o ote e q ip e t s d E a aio v lu t n 4 2 1 E a aio Sa d r v lu t n t n a d 8 %ra o e: 4 0 o bv 6 to7 % : 2 0 9 5 % rb lo : 1 9 o e w N ( r Ys b t it ta e to mn mn o r : 5 o o) e .Equipment Rating AE RA Po ut n r d c io 2 I th r b c u e u mn . 5 0 0: 4 Oe 2 L k s : 4 vr s 0 0 v r .

1 2 3 Cat A B C Specification Critical Moderate Non critical % contribution 34% 53% 13% Nos. “Best Practices in Maintenance Management” Pune .Machine Ranking TOTAL MACHINE STRATIFICATION 13% 34% A 53% B C Sr. 2010. 27 42 10 79 Total machines May 11.

2) 1. Use WHY-WHY-WHY JH Step 2 COUNTER MEASURES AGAINST SOURCES Ex-terminate 4 vices (DIRT.Support & Guidance to JH Activity JH . PM GROUP . RED Tag improvement plan Maintaining visuals controls and displaying labels. 2010. PRODUCTION SHOULD BE ABLE TO DO THESE ACTIVITIES WITHOUT HELP OF MAINT.SO WHAT JH Step 5 JH Step 6 STANDARDIZATION Autonomous PDCA (CAPD) “Best Practices in Maintenance Management” Pune JH Step 7 May 11. VIB) JH Step 3 SUPPORT FOR MAKING STANDARDS OF CLEANING. Types of oils etc. LUBRICATION & INSPECTION EDUCATION OF OVERALL INSPECTION FOR LEADER TRAINING TO IMPROVE MAINT RELATED TECHNICAL ABILITY M A I N T H E L P JH Step 4 From WHY WHY to SO WHAT .Step 1 RED TAG STRATEGY SUPPORT (1. RED Tag summary sheet and RED Tag plan 2. HEAT. RUST.

Failure analysis Combination of Failure Factors Inadequate basic conditions Lack of skills Leaving deterioration unrepaired Design shortcomings Non-observance of usage conditions May 11. 2010. “Best Practices in Maintenance Management” Pune .

2. May 11. 4. Kobetsu Kaizen Jishu Hozen Planned Maintenance Education & Training Development Mgmt. Keep operating conditions. Improve weak points in design.Countermeasures for Zero Failures 1. 5. “Best Practices in Maintenance Management” Pune . Restore the deterioration. Establish basic conditions. 2010. 3. Improve the skill level.

2010. “Best Practices in Maintenance Management” Pune .Data collection for breakdowns May 11.

WHY .WHY Analysis Oil leaks from cylinder rod each time it operates Question Answer What is your final action ? After replacing O-ring. is it OK WHY ANSWER O-ring cut Rod has scratch Chips were scattered and attached to rod Replacing the O-ring Yes ACTION O-ring changed Scratch removed Measures taken to prevent chips from scattering Cylinder’s position changed and cover fixed Standardise design and installation Why did you replace Oring Why O-ring out Why rod has scratch Why chips were attached to rod Why cylinder located within scattering range of chips and rod cover not replaced Cylinder located within scattering range of chips and rod cover is not placed Defective design and installation May 11. 2010. “Best Practices in Maintenance Management” Pune .

Electrical Electronics “Best Practices in Maintenance Management” Pune .Area wise Stratification of Phenomena's Total Phenomenon:94 Electronics. 2010. 14 Electrical. 25 Mechanical. 55 Mechanical May 11.

“Best Practices in Maintenance Management” Pune . 2010.Mechanical Area wise Occurrences Total : 414 Nos. 18 22 20 19 32 10 12 51 Fixture and seat check High Pressure coolant System Hydraulic System Auto Tool Changer Axis Rubber sheet 18 Coolant Spindle Table 63 72 Lubrication Air leakage 41 36 Burr Door May 11.

“Best Practices in Maintenance Management” Pune . 1 Kaizen. 39 Preventive Maintenance. 8 Training. 2010. 46 May 11. 17 CBM.Countermeasure for Zero breakdown (Mechanical) No root cause.

2010.Development of PM module Step1 2 PM Support & Guidance to JH Activities Evaluate Equipment and Understand Current Condition Restore forced & natural deterioration and Correct weaknesses 3 4 Build an Information management System Maintain flow of breakdown Analysis 5 MP CM Build a Periodic Maintenance System Build a Predictive Maintenance System Evaluate the Planned Maintenance System 6 7 May 11. “Best Practices in Maintenance Management” Pune .

Roles of PM and JH Implementation Classification Prevention Measurement Restoration Operati on Assigned Maintena nce Proper Operation Normal Operation Set-up and adjustment Cleaning. 2010. Daily Inspection for Deterioration Minor Check Time – based Inspection Time based Maintenance Productive Maintenance Time – based Inspection Time – based Check Trend Check Unscheduled Check Predictive Maintenance Strength KAIZEN Corrective Maintenance (Reliability) Lightening of Loading Accuracy Improvement Conditions Monitoring KAIZEN of Check Operation KAIZEN Of Check Operation Corrective Maintenance Corrective Maintenance (Maintain-ability) Others Maintenance Prevention Breakdown Maintenance MP Activities Planned Breakdown Maintenance Emergency Maintenance Check Quality KAIZEN Earlier discovery of interior situation and positive and rapid report/remedy Sporadic Repair May 11. Address Latent Defects Preventive Maintenance Daily Maintenance Lubrication Retightening Operation Condition. “Best Practices in Maintenance Management” Pune .

Cost Saving Activities 1) 1S and 2S Activities 1) Develop alternative source 2) TBM based procurement 2) In house manufacturing & repairs 3) Procurement Lead time reduction 4) Procurement of consumable spare through schedule agreement route May 11. 3) Re use after modification 4) Life enhancement “Best Practices in Maintenance Management” Pune 6-26 .Machinery spares parts management Spares Parts management A. Inventory Reduction B. 2010.

Mp Sheet Generation System May 11. 2010. “Best Practices in Maintenance Management” Pune .

M. 2010. “Best Practices in Maintenance Management” Pune .Break Down Hrs Status (Press shop) 1800 1500 1200 1200 90 4 BETTER Nos of Hours 72 3 66 0 900 62 2 61 1 42 5 42 5 600 54 0 55 2 30 0 30 5 28 4 24 4 300 21 0 11 2 0 B. Apr( Oct-06 to Mar-07 ) 07 May07 Jun07 Jul-07 Aug07 Sep07 Oct07 Nov07 Dec07 Jan08 Feb08 Mar08 Apr08 May08 Jun08 0 Tgt May 11.

Jun-08 08 0 Tgt May 11. Apr( Oct-06 to Mar-07 ) 07 May07 Jun-07 Jul-07 Aug07 Sep07 Oct-07 Nov07 Dec07 Jan-08 Feb08 Mar08 Apr08 May. “Best Practices in Maintenance Management” Pune . In Nos 200 15 5 14 5 14 5 12 5 12 5 20 5 11 4 12 0 11 4 10 2 99 85 65 55 12 100 0 B.Break Down Occurrence (Press Shop) 400 333 300 BETTER Occ.M. 2010.

6 1.1 2 33 % DOWN 1.2 1 0 B.Maintenance Cost 4 3 BETTER Percentage of sales 2. Tgt Actual Jun 08 Maintenance Cost Loss reduction Kaizen done 132 Nos May 11.M. 2010. “Best Practices in Maintenance Management” Pune .

Type defect OK B .Type defect NOT OK NOT OK NOT OK Action taken by operator No action by operator OK Action taken by operator LSL OK USL LSL OK USL LSL OK USL • The output is (OK) initially • Becomes (NG) • Corrective action is taken by operator • Becomes (OK) • Use Why – Why Analysis May 11.Defects classification A . 2010. • The output is (OK) initially • Becomes (NG) • No action taken by operator • Becomes (OK) • Use PM Analysis • The output is (NG) initially • Action taken by operator • Becomes (OK) (setting scrap) “Best Practices in Maintenance Management” Pune .Type defect OK C .

jigs. stationary). machining conditions WHERE Location May 11.KAIZEN EYE THEME PROBLEM (PRESENT STATUS) ANALYSIS (ROOT CAUSE) REDUCE / ELIMINATE / INCREASE / PREVENT CORRECT OBSERVATION 1. (summer. increase. Easy IDEA (OPPOSITE OF ROOT CAUSE) COUNTERMEASURE (Kaizen) RESULT BENEFIT WHEN Trend INCREASE PRODUCTION Continuous. Part. Long 8. winter. very rare REDUCE COST Phenomena stratified by 5W and 1H Time. Partly PROVIDING / CHANGING REDUCE TIME REDUCE FREQUENCY ELIMINATE PREVENT INCREASE LIFE 4. temporary help Lots. 2010. fore. season. type No.tools. Poka 2. Poka Yoke 2. -. night shift. Difficult 7. More Friction 3. process. reduction Equipment. period WHO WHAT WHICH HOW Men Materials Trend Status Start-up. Big 4. accuracy (dynamic. Coolant 6. “Best Practices in Maintenance Management” Pune . Cannot detect 9. Short 8. Small 7. left and right). Many Bolts 5. Fully 1. rainy season). new employees. setup Day shift. Less Friction 3. Less Bolts 5. No coolant 6. range. discontinuous. Can detect 9. equipment Direction (+. rear.

2)Mr.Zanwar. Status Root cause : Hard to access 0 . How to Sustain : Irreversible 50 30 5 Scope and Plan for HD No M/ C T/date Res.Nov 09 ' Dec-09 1 6 12.kachke Door cylinder Analysis: Why1: Door speed Setting time more Why2: Guard has to removed for setting. 09 ASJ Comp. 3)Mr.Kaizen Idea Sheet Activity Result Area Defect Type KK P JH Q QM C PM D SH S OTPM M DM ET Shop: M/C: Kaizen Theme:To reduce setting time speed .k. Door cylinder Window for air flow setting Bench Mark Target Kaizen Start Kaizen Finish Team Members: 1)Mr.11. Why3: Hard to access Result: Door speed setting time reduced 100 Benefits: 1)Machine availability improved.S. No: for door Kaizen Idea: Easy to Access 2 Case study 30 Min 5 Min 2/11/09 3/11/09 Countermeasure: Provided the window cut out on guard for air flow setting.Joshi.K. Time in Min.A.O. Problem/Present Status: On FRD machine for door speed setting time is more No window cut out Reg. .B.

2010. GAP GAP GAP “Best Practices in Maintenance Management” Pune .Loss Tree DESPATCH PRODUCTION OEE AVAILABILITY B/D SET UP TOOL CHANGE START UP INVENTORY NO ORDER PERFORMANCE PM REDUCED SPEED HOLIDAY QUALITY MINOR STOPS SCRAP R/W ADJUSTMENT JH PM KK KK KK KK QM QM GAP GAP GAP May 11.

TAXES. 2010.Cost Loss Tree MANUFACTURING COST FIXED LABOUR MFG SUPPORT VARIABLE REPAIR & MAINT PERSONEL WELFARE ADMIN COST& PROF FEE RATE. “Best Practices in Maintenance Management” Pune . INSURANCE BUILDING SPARES DEPRECIA-TION LOL OML R/W HRS B/D CONS UM KK KK QM PM PM GAP GAP GAP May 11.

PV Patil 23-July-08 Prepared By MKP  Basic Knowledge Improvement classes Trouble class METHOD OF USING ALLEN KEY Correct method Allen key is fully inserted in the socket before tighten or loosen the bolt. “Best Practices in Maintenance Management” Pune . Allen key Allen key DATE EXECUTED TEACHER STUDENT May 11. Date of preparation.M.TPM One Point Lesson Theme Related to Classification METHOD OF USING ALLEN KEY CLEAN LUBRICATE INSPECT RETIGHTEN P. 2010. Engr. Wrong method Allen key is partially inserted in the socket before tighten or loosen the bolt. No. MK Mgr.

DIAGNOSTIC TECHNIQUE + SERVICE LIFE PREDICTION J.Key Activities DETERIORATION Planned Maintenance TIME T B M 2 Life Extension 2 T [CM] B M 1 FORCED DETERIORATION Life Extension 1 JH LIMITING CONDITION J. KAIZEN KOBETSU KAIZEN EDUCATION + TRAINING SHE “Best Practices in Maintenance Management” Pune . HOZEN STEP(4) (6) ELIMINATION OF FORCED DETERIORATION C B M RESTORATION OF BASIC CONDITION REDUCTION IN SPORADIC FAILURES RELIABILITY BASED MAINT.M PM EXTENTION OF WORKING LIFE (IMP. HOZEN Q.OF WK.PTS OF DESIGN)& ELIMINATION OF CHRONIC PROBLEMS MP DESIGN + INITIAL CONTROL May 11. 2010.

Tool change. TPM) Restoration of unsafe action & place  Additional Restoration after patrol  Development Management Office TPM May 11. Cleaning. Lubrication. Start-up etc. Top management) Jishu Hozen Meeting Jishu – Hozen (Autonomous Maintenance) Education and Training Safety.TPM Activity Quality Maintenance Physical phenomenon of Defect • Customer Complaint WHAT In-house Rejection & Rework  Kobetsu Kaizen (Focussed Improvement) Planned Maintenance LOSS • Set-up. Health & Environment • • • • • • • Program (Subject) Patrol Education Kaizen ( Countermeasure) Design Review Meeting Cost. TBM • Replacement.Role of Pillars. MTTR. Section. Lead time reduction. After Inspection • • • Stepwise ( Abnormalities List is separated) Audit ( Self. minor stop. Cost) • Additional Countermeasure. “Best Practices in Maintenance Management” Pune . Inspection. Overhaul • JH Kaizen (request)  Kaizen ( MTBF. Quality Purchasing department – Advising to supplier ( Quality. 2010. Motion loss.

2010. “Best Practices in Maintenance Management” Pune .Planned Maintenance May 11.

Thank You May 11. 2010. “Best Practices in Maintenance Management” Pune 68 .

Sign up to vote on this title
UsefulNot useful