TPM: Planned Maintenance (PM)

1. Planned Maintenance © Operational Excellence Consulting. All rights reserved. © Operational Excellence Consulting. All rights reserved.

2. NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg Learning Objectives Understand what is Planned Maintenance and why it is important in TPM implementation Gain knowledge on the JIPM TPM Excellence Criteria for Planned Maintenance Describe the seven implementation steps of Planned Maintenance Acquire knowledge on how to plan and organize Planned Maintenance activities 2 © Operational Excellence Consulting. All rights reserved.

3. Contents 1 1 Introduction to Planned Maintenance 2 2 What is Planned Maintenance? 3 3 Planning & Organizing for Planned Maintenance 4 4 The 7 Steps of Planned Maintenance JIPM TPM Excellence Criteria for Planned Maintenance 5 5 3 © Operational Excellence Consulting. All rights reserved.

4. The Vicious Cycle Of Poor Equipment Reliability No time for Planned Maintenance activities High frequency of equipment breakdowns POOR RELIABILITY ? UNHAPPY CUSTOMER Extensive emergency repairs Fire-fighting Does your maintenance department look like this? 4 © Operational Excellence Consulting. All rights reserved.

5. From PM to TPM Developed in Japan Originated in the United States Preventive Maintenance Productive Maintenance TPM Traditional PM (Commonly called “PM”) PM in TPM Centered in maintenance departments Everyone takes part Source: Based on JIPM 5 © Operational Excellence Consulting. All rights reserved.

6. “Minimizing manufacturing costs is achieved primarily by improving the productivity of all the machines on the factory floor, both bottleneck and non-bottleneck machines alike. This is a daunting challenge unless the entire organization pitches in and applies proven methods to the task.” JAMES A. LEFLAR Author of “Practical TPM” 6 6 © Operational Excellence Consulting. All rights reserved. © Operational Excellence Consulting. All rights reserved.

7. What Is TPM? Maximize efficiency Entire equipment life cycle Coordinates all departments Involves everyone Team-based activities The goal of TPM is to build a robust enterprise by maximizing production system efficiency (overall effectiveness) TPM addresses the entire production system life cycle and builds a concrete, shop-floor based system to prevent all losses. Its aims include the elimination of all accidents, defects and breakdowns. TPM involves all departments, from production to development, sales, and administration Everyone TPM achieves zero losses, through overlapping team activities participates in TPM, from top executives to shopfloor employees 7 © Operational Excellence Consulting. All rights reserved.

8. Overview of TPM Planned Maintenance Is One Of The Foundational Pillars Of TPM TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents Safety, Health & Environment Autonomous Maintenance Focused Improvement Planned Maintenance Education & Training Quality Maintenance Early Equipment Management Office TPM 5S & Visual Management Planned Maintenance aims to increase production efficiencies by eliminating breakdown losses. 8 © Operational Excellence Consulting. All rights reserved.

9. Difference Between Failure & Breakdown Failure Breakdown A failure occurs when equipment condition reaches an unacceptable level, even if it remains functional A breakdown occurs when the equipment stops functioning § § Breakdown is the result of failure and the effect that failure has over the failure developing period § This is a failure because even though the equipment is still functional, the subpar condition affects output and creates a precedent for breakdown — dubbed the failure developing period § For example, if the temperature of your electric motor remains too high, it can cause the shaft to snap, creating a breakdown § 9 © Operational Excellence Consulting. All rights reserved.

10. TPM – Three Principles Of Prevention Maintenance Of Normal Conditions Early Discovery Of Abnormalities Prompt Response To maintain normal operating conditions, operators prevent deterioration by cleaning, checking, oiling, tightening, and precision-checking the equipment on a daily basis While performing these activities, operators use their senses and measurement tools to detect abnormalities as soon as they appear. Maintenance workers also conduct periodic diagnostic tests to check for abnormalities using specialized tools. Operators and maintenance staff respond immediately to abnormalities 10 © Operational Excellence Consulting. All rights reserved.

11. What Is Planned Maintenance? Planned Maintenance is a proactive approach to maintenance that focuses on minimizing the downtime and costs associated with breakdowns. 11 © Operational Excellence Consulting. All rights reserved.

12. The Basic Idea Of Planned Maintenance: Fix It Before It Breaks 12 © Operational Excellence Consulting. All rights reserved.

13. Dual Focus of Planned Maintenance Improvement of Improvement of Equipment Maintenance Skills 13 © Operational Excellence Consulting. All rights reserved.

14. Difference Between Planned And Preventive Maintenance § The terms planned and preventive maintenance are often used somewhat interchangeably, but they are not the same thing § Preventive maintenance • Is the most common type of planned maintenance • It refers to maintenance tasks that you schedule and perform while an equipment is still working to prevent it from failing unexpectedly § Planned maintenance • Refers to any strategy where you plan and perform maintenance tasks before a fault occurs 14 © Operational Excellence Consulting. All rights reserved.

15. Difference Between Autonomous Maintenance and Planned Maintenance Autonomous Maintenance Planned Maintenance Prevents accelerated deterioration of machine parts Prevents unplanned breakdown losses § § Addresses specific equipment-related losses that reduce OEE § Provides the underpinning to uphold the benefits of routine maintenance and Focused Improvement over the long term § Uses data for analysis and planning § Performed by maintenance personnel § Performed by operators § 15 © Operational Excellence Consulting. All rights reserved.

16. Benefits of Planned Maintenance Enables Maintenance Planning Reduces Unplanned Downtime Reduces Spares Inventory Enables most maintenance to be planned for times when equipment is not scheduled for production Significantly reduces instances of unplanned downtime Reduces inventory through better control of wear-prone and failure-prone parts 16 © Operational Excellence Consulting. All rights reserved.

17. Policy of Planned Maintenance § Achieve and sustain availability of machines § Optimum maintenance cost § Reduces spares inventory § Improve reliability and maintainability of machines 17 © Operational Excellence Consulting. All rights reserved.

18. Planned Maintenance – Two Main Activities IMPROVEMENT OF MAINTENANCE SKILLS àMTTR IMPROVEMENT OF EQUIPMENT àMTBF § Preventive Maintenance § Specialized maintenance skills § Corrective Maintenance § Equipment repair skills § Maintenance Prevention § Inspection and measurement skills § Breakdown Maintenance § Equipment diagnostic skills § Support for Autonomous Maintenance § Develop new maintenance technologies 18 © Operational Excellence Consulting. All rights reserved.

19. Planned Maintenance Provides A System To Achieve The Natural Life Cycle Of Individual Equipment Elements § Correct operation § Correct set-up § Cleaning § Lubrication § Retightening § Feedback and repair of minor defects § Quality spare parts 19 © Operational Excellence Consulting. All rights reserved.

20. Elements Of A General Maintenance Plan 1. Maintenance vision and mission statements 2. Maintenance tasks 3. Standard operating procedures 4. Maintenance schedule 5. Maintenance staffing and skills development 6. Spare parts management 7. Engineering and third-party contractors 20 © Operational Excellence Consulting. All rights reserved.

21. TPM Implementation Organization Structure With Planned Maintenance Pillar TPM Responsible (Plant Manager) TPM Promotion Office The company should focus on these four pillars during the first three years of TPM implementation Planned Maintenance Education & Training Focused Improvement Autonomous Maintenance Safety, Health & Environment Early Equipment Management Office TPM Quality Maintenance 21 © Operational Excellence Consulting. All rights reserved.

22. Tasks for Maintenance Department § Tasks requiring special skills (beyond the capability of operators) § Overhaul repair in which deterioration is not visible from the outside § Repairs to equipment that is hard to disassemble and reassemble § Tasks requiring special measurements § Tasks posing substantial safety risks, such as working in high places Source: TPM for Workshop Leaders by Kunio Shirose 22 © Operational Excellence Consulting. All rights reserved.

23. Key Roles Of Operations & Maintenance Divisions Maintenance increases equipment reliability and minimizes maintenance cost by reducing breakdowns and developing efficient maintenance methods Operations maximizes production outputs through efficient use of resources and takes responsibility for routine maintenance Maintenance Operations Operations and Maintenance have tremendous ability to impact profitability through collaboration and change. 23 © Operational Excellence Consulting. All rights reserved.

24. Roles Of The Maintenance Department Figure 2: Roles of the Maintenance Department Maintenance Activities to be Performed Maintenance Classification Preventing Deterioration Measuring Deterioration Rectifying Deterioration Periodic inspection Periodic examination Periodic Maintenance Periodic shutdown Trend control Unscheduled shutdown Predictive Maintenance Sporadic repair Breakdown Maintenance Early detection of situation and speedy countermeasures Enhancement of material strength Corrective Maintenance (Reliability) Reduction of load Enhancement of accuracy Development of condition monitoring Improvement of maintenance work Corrective Maintenance (Maintainability) Enhancement of maintenance quality Improvement of inspection work 24 © Operational Excellence Consulting. All rights reserved.

25. Maintenance & Control § Improvements in MTBF are accomplished through the support of AM activities and the implementation of the four maintenance types discussed previously: • Breakdown maintenance • Periodic maintenance • Predictive maintenance • Corrective maintenance 25 © Operational Excellence Consulting. All rights reserved.

26. The 4 Phases to Zero Breakdowns Phase 3 Phase 4 Phase 1 Eliminate forced deterioration Phase 2 Extend lifetimes through corrective maintenance Monitor and control deterioration Carry out predictive maintenance 26 © Operational Excellence Consulting. All rights reserved.

27. The 7 Steps Of Planned Maintenance 7 Evaluate The Planned Maintenance System 6 Build A Predictive Maintenance System 5 Build A Periodic Maintenance System 4 Build An Information Management System 3 Restore Deterioration And Correct Weaknesses Evaluate Equipment And Understand Current Condition 2 Provide Support And Guidance To Autonomous Maintenance Activities 1 27 © Operational Excellence Consulting. All rights reserved.

28. Step 3 – Restore Deterioration And Correct Weaknesses § Extend help to operators to prepare ‘tentative standards’ for cleaning, lubrication and inspection for each machine § Specify clearly what the operators are supposed to do under Autonomous Maintenance and what the maintenance engineers are supposed to do under Planned Maintenance § Use provisional standards for checking and replacement intervals § Examine each machine and identify the parts that should be subjected to preventive maintenance § Establish schedules for TBM and CBM 28 © Operational Excellence Consulting. All rights reserved.

29. How to Sustain TPM & Planned Maintenance Activities § Providing active leadership § Engaging employees § Aim for early success § Share success stories § Rewards and recognition § Continuously reduce equipment losses § Evolving the TPM initiative over time and integration with Lean 29 © Operational Excellence Consulting. All rights reserved.

30. Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. Based in Singapore, the firm’s mission is to create business value for organizations through innovative design and operational excellence management training and consulting solutions. For more information, please visit www.oeconsulting.com.sg 30 © Operational Excellence Consulting. All rights reserved.