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Maintenance Management

Maintenance management is planning,

organizing, and controlling maintenance
activities such that the overall maintenance
cost is the minimum.

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 Total Productive Maintenance

Total productive maintenance (TPM) seeks

to maximize equipment effectiveness
throughout the lifetime of that equipment.

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Benefits of Maintenance Management

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 Types of Maintenance

There are basically two types of maintenance:

Breakdown maintenance is a reactive approach in

which repairs and replacement of parts are performed
only when the breakdowns occur.

In preventive maintenance, which is a proactive

approach, breakdowns are avoided by following regular
schedules of oiling, cleaning, adjustment, inspection,
and replacement of worn-out parts in the equipment.

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Types of Maintenance Costs

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The Eight Pillars of TPM

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 Why-Why Analysis

To illustrate the power of Why-Why analysis, Ohno often cited the

following example (Ohno 1978):
1. ‘ “Why did the robot stop?’
The circuit has overloaded, causing a fuse to blow.
2. ‘Why is the circuit overloaded?’
There was insufficient lubrication on the bearings, so they locked
up.
3. ‘Why was there insufficient lubrication on the bearings?’
The oil pump on the robot is not circulating sufficient oil.
4. ‘Why is the pump not circulating sufficient oil?’
The pump intake is clogged with metal shavings.
5. ‘Why is the intake clogged with metal shavings?’
Because there is no filter on the pump.
Action Recommended: Install filter on the pump.

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