9 Productive Maintenance There are four components to a productive maintenance program:Elimination of equipment lossesPreventive maintenancePredictive or planned maintenanceAutonomous maintenance
10 Productive Maintenance Elimination of Equipment Losses: Prevent DowntimeEliminate Breakdowns, the loss or reduction of a specified function, which cause production losses, spoilage, lost time.Avoid Stops, Jams and Standbys that occur randomly and cause production lost time.
11 Productive Maintenance Elimination of Equipment Losses: Prevent DowntimeEliminate losses byRoot Cause AnalysisSearch out and correct all the slight defects in parts and jigs involved in transfer of workAutonomous MaintenanceProper maintenance over time is a good defense.Training to Create a Better Understanding of the Equipment
12 Productive Maintenance Elimination of Equipment Losses: Prevent speed lossDesign speeds vs. actual operation speedChanges to part/equipment may make it impossible to run at design speedNeed to determine optimal running speeds during productionCorrect insufficient debugging, defective mechanisms, design weakness, insufficient equipment, increase precision
13 Productive Maintenance Elimination of Equipment Losses: Reduce Quality DefectsFind root causes and eliminate them in the design of products, processes and machines.Five Improvement Toolsa) Paretob) Problem analysisc)Ask why 5 timesd) Cause and Effecte) PM Analysis
14 Productive Maintenance Measure progress toward elimination of equipment losses by:Measuring the number of occurrences of breakdowns, jams, and standbysMeasuring the duration of breakdowns, jams, and standbysMeasuring spoilage ratesMeasuring production ratesMeasuring mean-time-between-failuresUtilizing run charts to track performance
15 Productive Maintenance Preventive MaintenancePreventive maintenance maintains the equipment in good condition so that unexpected downtime does not occur.
16 Productive Maintenance Preventive MaintenancePeriodic inspection of equipment to detect conditions that might cause breakdowns and then follow-up action to reverse such conditionsScheduled maintenanceStart with high priority equipment
17 Productive Maintenance Preventive Maintenance1) Perform Long term MaintenancePlanScheduleExecute2) Create StandardsEstablishAdhere toReview periodically
18 Productive Maintenance Preventive Maintenance3)Create PlansMust plan for scheduled maintenanceWhat interval?Annual?monthly?How will down-time be scheduled?How much time to repair?major overhaul?Have parts/materials been procured?Has outside labor been scheduled?Will budget cover the cost?
19 Productive Maintenance Preventive Maintenance4)Maintain RecordsDocumentation of machine performanceProvides historyhelps with planning maintenanceThese records are used to assess equipment conditions, establish priorities, deploy resourcesDaily or periodic inspections provide recordsPriorities based on production importance, quality level, maintenance history, safety
20 Productive Maintenance Preventive Maintenance4) Maintain RecordsWhat records are needed?Why needed?How used?
21 Productive Maintenance Preventive Maintenance4) Maintain RecordsSimplify and Standardize Current Record-Keeping ProceduresRoutine inspection recordsLubricant replenishment/replacement recordsPeriodic inspection recordsRepair and service reportsMaintainability improvement records
22 Productive Maintenance Preventive Maintenance4) Maintain RecordsSimplify and Standardize Current Record-Keeping ProceduresMTBF analysisEquipment LogsMaintenance Cost RecordsBreakdown analysis recordsDowntime occurrences and time
23 Productive Maintenance Preventive Maintenance5) Spare parts controlNecessary spare parts available when needed without having it sit around and go badAnalyze need, priority, storage method, restocking method, cost of stock
24 Productive Maintenance Preventive Maintenance6) Maintenance CostsOften over-budgetlack of planningfire fighting verses preventionnot knowing real costs of wasteImprove this by:Building awarenessMonitoring expenditures closelyResponding to deviations quickly
25 Productive Maintenance Preventive Maintenance6) Maintenance CostsReduce Costs by1) Forming Preventive Maintenance Teams2) Eliminating Equipment Losses3) Reviewing periodic maintenance intervals4) Switching from outside contracting to in-house fabrication5) Reducing permanently stocked spare parts6) Using idle equipment effectively7) Reducing energy and resource use
26 Productive Maintenance Preventive Maintenance7) Lubrication ControlProper lubricationoils, cutting oils, greases, solid lubricantsNo leakageNo contaminantsControlling the deterioration/contamination of lubricantsdaily inspectionLevelsTimeRate of usage
27 Productive Maintenance Predictive MaintenancePredictive maintenance schedules routine maintenance so that everyone knows and can plan for a machine or a piece of equipment being unavailable.
28 Productive Maintenance Predictive MaintenanceMeasuring, recognizing and using signals from process to diagnose the condition of the equipment and determine when maintenance will be requiredCost of monitoring should be less than cost of repair or production losses
29 Productive Maintenance Predictive MaintenanceMaintenance PreventionDesign and acquisition of equipment that will be easy to maintain and operateComes from equipment historyMTBF, time to overhaulExperienceSafety Records
30 Productive Maintenance Predictive MaintenanceMaintenance Skill TrainingMaintenanceWorkers with strong maintenance and equipment related skillsAn understanding of equipmentDevelop expertise and skills
31 Productive Maintenance Autonomous MaintenancePerformed by equipment operatorsDaily cleaning, inspecting, lubricating, bolt tightening; prevents equipment deterioration.15 min/dayTransfers ownership to person running machine
32 Productive Maintenance Autonomous Maintenance Steps:1) Thoroughly clean all equipmentmay take place during plant shutdown
33 Productive Maintenance Autonomous Maintenance Steps:2) Make FUTURE cleaning easier and faster by:Improving access to equipmentEliminating sources of contaminationEstablishing standard operating proceduresMaking sure correct items are on hand (proper lubricants, cleaners, etc…)
34 Productive Maintenance Autonomous Maintenance Steps3) Basic TrainingTeach correct procedures, settings, adjustmentsTeach problem detectionTeach problem resolution