Planned Maintenance

Technique

DOWNTIME
 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
 PLANNED MAINTENANCE
TECHNIQUE

WHAT IS THE EFFECT OF POOR

MAINTENANCE ACTIVITIES?
•INVENTORY > MORE THAN IS NEEDED
•LEAD TIME > SLOWER THAN NECESSARY
•QUALITY > NOT AS GOOD AS IT COULD BE
•COST > HIGHER THAN YOUR COMPETITORS
•CAPACITY > LOWER THAN IT COULD BE
•NEW BUSINESS > MAY NOT BE ABLE TO CAPTURE
PLANNED MAINTENANCE
TECHNIQUE - Safety

SAFETY WILL NOT

BE COMPROMISED !!!
 PLANNED MAINTENANCE
TECHNIQUE - Goal

THE GOAL IS TO ACHIEVE THE

ABSOLUTE MINIMUM AMOUNT OF
TIME NEEDED FOR EFFECTIVE
MAINTENANCE.
 PLANNED MAINTENANCE
TECHNIQUE - More Waste

WASTE OF:
• INVENTORY
• OVERPRODUCTION
• CORRECTION
• MATERIAL & INFORMATION
MOVEMENT
• PROCESSING
• WAITING
• MOTION
 Types of Maintenance

FOUR TYPES OF MAINTENANCE

REACTIVE PREVENTIVE

PREDICTIVE PREVENTION
 PLANNED MAINTENANCE
TECHNIQUE - Activity Model
MAINTENANCE ACTIVITY MODEL
NON-DISCRETIONARY DISCRETIONARY
- REARRANGEMENTS
- MODIFICATIONS
- CONSTRUCTION

PROACTIVE REACTIVE
(SCHEDULED) (UNSCHEDULED)
- BREAKDOWNS
- REPAIR
- EMERGENCIES

PREDICTIVE PREVENTIVE
- VIBRATION ANALYSIS - VISUAL INSPECTION
- INFRARED - TIME SCHEDULING
- FIBER OPTICS - HOURS OF USAGE
- ULTRASONIC - MINOR REPAIR
- MACHINE HISTORIES
 Reactive 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 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 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 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 Six Big Losses

DOWNTIME:
1. BREAKDOWNS DUE TO EQUIPMENT FAILURE
2. SET-UP AND ADJUSTMENT

SPEED LOSSES:
3. IDLING AND MINOR STOPPAGES
4. REDUCED SPEED

DEFECTS:
5. SCRAP AND QUALITY DEFECTS
6. REDUCED YIELD
 Breakdown Causes

• BASIC CONDITIONS NEGLECTED

• INADEQUATE SKILLS

• OPERATING STANDARDS NOT FOLLOWED

• DETERIORATION UNCHECKED

• INHERENT DESIGN WEAKNESS