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

What is FORCED DETERIORATION?

Equipment Condition

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

OE E TRE 8% AGT 5

TARGET

I p vm t moe e r n A i ii s cv e t t Ai ii s cv e t t

Mn nne a t ac i e

B adw r ko n e
MI T I A I I Y A A B T N N L

P v nv r et e e i M t nne a eac in

Pi d eoi r c Dly a t nne a Mn ac i i e N m oe tos o a pr i n r l a Mn nne a t ac i e

RL B I Y EI I T AL Mn nne a t ac i e

METHOD

Cai g s l n a e n I seto npc n i

Su & ep t A s et d t n ju m s

Ri ad p T n Ts r d et e s A o ate b r lis n mi P i d Ts eoi et r c s

Strengthen Reduce Load Increase Precision

Classification & Allocation of Maintenance Activities

Gopalakrishnan - Role Of Maintenance
Condition Monitor Test Procedures Standardization ENG ENG Ra e i pr R tf e iy c ENG ENG

ACTIVITIES Prevent / Measure / Restore

Sv e ei rc

ALLOCATION Operators / Engineers

OP

OP

OP

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 USE KNOW UNDERSTAND

• Maintenance Prevention

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

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