Best Practice in Maintenance Tpm | Reliability Engineering | Quality

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

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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

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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.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

May 11. “Best Practices in Maintenance Management” Pune 23 .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. Support by PM Pillar Cost Awareness / Cost Effective Programs.

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

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

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

. Nos Hrs/emp/month Z 0 B V May 11. “Best Practices in Maintenance Management” Pune 27 .Targets Current Status Activity Breakdown hrs. Hrs Nos. No.10 Feb. of Phenomenon UOM BM Dec. In Lac Nos.09 Jan./Piece Rs /piece X Y C Rs.Planned Maintenance . 2010.10 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.

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

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

Stds. and TBM Equip. 2010.PM Pillar Methodology Study of past Equipment History Ranking of Equipment Support to JH Preparation of JH3 tent. 30 . 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.

“Best Practices in Maintenance Management” Pune . 2010.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.

5 0 0: 4 Oe 2 L k s : 4 vr s 0 0 v r . 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 . 3 0 : 1 vr s 0 0 ne s 00 R. ws dc th ws dpo u tio e ) B r e u b r a te lo . 5 0 : 4 Ud r 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 h t xe t o s a r f e t e ok n ir n e t ( en is . 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 .5 a h 2 0 0~5 0 0 : 2 1L k ~2 l k : 2 50 00 a h . 2010. 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 . 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 . S mwa o e ht : 2 Nt S n ic n : 1 o ig if a tly Oe R. 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 ? .Equipment Rating AE RA Po ut n r d c io 2 I th r b c u e u mn . 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. 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 . “Best Practices in Maintenance Management” Pune .5a h Ud r2 0 0 : 1 Ud r1L k ne 50 ne a h :1 Dc iv ly e is e :5 4 . a e f o th c a s e ( un dr b e . 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 . 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 . f ms d s ec lik o e u e .

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

VIB) JH Step 3 SUPPORT FOR MAKING STANDARDS OF CLEANING. 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. 2) 1. HEAT.SO WHAT JH Step 5 JH Step 6 STANDARDIZATION Autonomous PDCA (CAPD) “Best Practices in Maintenance Management” Pune JH Step 7 May 11. RED Tag improvement plan Maintaining visuals controls and displaying labels. PM GROUP . 2010. RUST. RED Tag summary sheet and RED Tag plan 2. Use WHY-WHY-WHY JH Step 2 COUNTER MEASURES AGAINST SOURCES Ex-terminate 4 vices (DIRT. PRODUCTION SHOULD BE ABLE TO DO THESE ACTIVITIES WITHOUT HELP OF MAINT.Support & Guidance to JH Activity JH . Types of oils etc.

“Best Practices in Maintenance Management” Pune .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.

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

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

2010. “Best Practices in Maintenance Management” Pune .WHY . 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.WHY Analysis Oil leaks from cylinder rod each time it operates Question Answer What is your final action ? After replacing O-ring.

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

“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.

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

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. 2010. “Best Practices in Maintenance Management” Pune .

Address Latent Defects Preventive Maintenance Daily Maintenance Lubrication Retightening Operation Condition. “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.

2010.Machinery spares parts management Spares Parts management A. 3) Re use after modification 4) Life enhancement “Best Practices in Maintenance Management” Pune 6-26 . 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. Inventory Reduction B.

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

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. “Best Practices in Maintenance Management” Pune . 2010.M. 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.

Break Down Occurrence (Press Shop) 400 333 300 BETTER Occ. 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.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. 2010. “Best Practices in Maintenance Management” Pune .M.

2010.6 1.M.2 1 0 B. “Best Practices in Maintenance Management” Pune . Tgt Actual Jun 08 Maintenance Cost Loss reduction Kaizen done 132 Nos May 11.1 2 33 % DOWN 1.Maintenance Cost 4 3 BETTER Percentage of sales 2.

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. • 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 . 2010.Type defect OK B .Type defect OK C .Defects classification A .

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

k. Problem/Present Status: On FRD machine for door speed setting time is more No window cut out Reg. Door cylinder Window for air flow setting Bench Mark Target Kaizen Start Kaizen Finish Team Members: 1)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 . How to Sustain : Irreversible 50 30 5 Scope and Plan for HD No M/ C T/date Res. 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. Time in Min. 09 ASJ Comp.O.Zanwar.A.kachke Door cylinder Analysis: Why1: Door speed Setting time more Why2: Guard has to removed for setting.11. .B.Joshi.Nov 09 ' Dec-09 1 6 12.K. Why3: Hard to access Result: Door speed setting time reduced 100 Benefits: 1)Machine availability improved.S. 2)Mr. 3)Mr. Status Root cause : Hard to access 0 .

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. 2010. GAP GAP GAP “Best Practices in Maintenance Management” Pune .

2010. TAXES. “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.Cost Loss Tree MANUFACTURING COST FIXED LABOUR MFG SUPPORT VARIABLE REPAIR & MAINT PERSONEL WELFARE ADMIN COST& PROF FEE RATE.

M.TPM One Point Lesson Theme Related to Classification METHOD OF USING ALLEN KEY CLEAN LUBRICATE INSPECT RETIGHTEN P. MK Mgr. Date of preparation. “Best Practices in Maintenance Management” Pune . Allen key Allen key DATE EXECUTED TEACHER STUDENT May 11. Wrong method Allen key is partially inserted in the socket before tighten or loosen the bolt. 2010. Engr. 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. No.

OF WK. HOZEN Q.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. 2010. 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. KAIZEN KOBETSU KAIZEN EDUCATION + TRAINING SHE “Best Practices in Maintenance Management” Pune . DIAGNOSTIC TECHNIQUE + SERVICE LIFE PREDICTION J.PTS OF DESIGN)& ELIMINATION OF CHRONIC PROBLEMS MP DESIGN + INITIAL CONTROL May 11.

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

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

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

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