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Productive Maintenance

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Presentation on theme: "Productive Maintenance"— Presentation transcript:

1 Productive Maintenance
Chapter 15

2 Productive Maintenance
Vision: Total life cycle equipment management Seeks to measure and improve overall equipment effectiveness

3 Productive Maintenance
Benefits Reduce costs Reduced inventories Reduce lead-time Reduce injuries Reduce breakdowns (jams, standbys, speed losses, startup losses, quality, etc…)

4 Productive Maintenance
Benefits Improved customer satisfaction Improved productivity Improved work environment Improved quality Improved change-over times

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Benefits Eliminate Waste Wasted Time Wasted Resources

6 Productive Maintenance
Where do production losses come from? Quality/non conformance issues Raw materials shortages Machines or equipment availability Cycle time losses

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Productive Maintenance seeks to improve Overall Equipment Effectiveness (OEE) OEE = Availability x efficiency x quality OEE is typically 50-60%, can climb to 80%

8 How will we accomplish this?

9 Productive Maintenance
There are four components to a productive maintenance program: Elimination of equipment losses Preventive maintenance Predictive or planned maintenance Autonomous maintenance

10 Productive Maintenance
Elimination of Equipment Losses: Prevent Downtime Eliminate 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.

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Elimination of Equipment Losses: Prevent Downtime Eliminate losses by Root Cause Analysis Search out and correct all the slight defects in parts and jigs involved in transfer of work Autonomous Maintenance Proper maintenance over time is a good defense. Training to Create a Better Understanding of the Equipment

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Elimination of Equipment Losses: Prevent speed loss Design speeds vs. actual operation speed Changes to part/equipment may make it impossible to run at design speed Need to determine optimal running speeds during production Correct insufficient debugging, defective mechanisms, design weakness, insufficient equipment, increase precision

13 Productive Maintenance
Elimination of Equipment Losses: Reduce Quality Defects Find root causes and eliminate them in the design of products, processes and machines. Five Improvement Tools a) Pareto b) Problem analysis c)Ask why 5 times d) Cause and Effect e) PM Analysis

14 Productive Maintenance
Measure progress toward elimination of equipment losses by: Measuring the number of occurrences of breakdowns, jams, and standbys Measuring the duration of breakdowns, jams, and standbys Measuring spoilage rates Measuring production rates Measuring mean-time-between-failures Utilizing run charts to track performance

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Preventive Maintenance Preventive maintenance maintains the equipment in good condition so that unexpected downtime does not occur.

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Preventive Maintenance Periodic inspection of equipment to detect conditions that might cause breakdowns and then follow-up action to reverse such conditions Scheduled maintenance Start with high priority equipment

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Preventive Maintenance 1) Perform Long term Maintenance Plan Schedule Execute 2) Create Standards Establish Adhere to Review periodically

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Preventive Maintenance 3)Create Plans Must plan for scheduled maintenance What 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?

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Preventive Maintenance 4)Maintain Records Documentation of machine performance Provides history helps with planning maintenance These records are used to assess equipment conditions, establish priorities, deploy resources Daily or periodic inspections provide records Priorities based on production importance, quality level, maintenance history, safety

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Preventive Maintenance 4) Maintain Records What records are needed? Why needed? How used?

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Preventive Maintenance 4) Maintain Records Simplify and Standardize Current Record-Keeping Procedures Routine inspection records Lubricant replenishment/replacement records Periodic inspection records Repair and service reports Maintainability improvement records

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Preventive Maintenance 4) Maintain Records Simplify and Standardize Current Record-Keeping Procedures MTBF analysis Equipment Logs Maintenance Cost Records Breakdown analysis records Downtime occurrences and time

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Preventive Maintenance 5) Spare parts control Necessary spare parts available when needed without having it sit around and go bad Analyze need, priority, storage method, restocking method, cost of stock

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Preventive Maintenance 6) Maintenance Costs Often over-budget lack of planning fire fighting verses prevention not knowing real costs of waste Improve this by: Building awareness Monitoring expenditures closely Responding to deviations quickly

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Preventive Maintenance 6) Maintenance Costs Reduce Costs by 1) Forming Preventive Maintenance Teams 2) Eliminating Equipment Losses 3) Reviewing periodic maintenance intervals 4) Switching from outside contracting to in-house fabrication 5) Reducing permanently stocked spare parts 6) Using idle equipment effectively 7) Reducing energy and resource use

26 Productive Maintenance
Preventive Maintenance 7) Lubrication Control Proper lubrication oils, cutting oils, greases, solid lubricants No leakage No contaminants Controlling the deterioration/contamination of lubricants daily inspection Levels Time Rate of usage

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Predictive Maintenance Predictive maintenance schedules routine maintenance so that everyone knows and can plan for a machine or a piece of equipment being unavailable.

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Predictive Maintenance Measuring, recognizing and using signals from process to diagnose the condition of the equipment and determine when maintenance will be required Cost of monitoring should be less than cost of repair or production losses

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Predictive Maintenance Maintenance Prevention Design and acquisition of equipment that will be easy to maintain and operate Comes from equipment history MTBF, time to overhaul Experience Safety Records

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Predictive Maintenance Maintenance Skill Training Maintenance Workers with strong maintenance and equipment related skills An understanding of equipment Develop expertise and skills

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Autonomous Maintenance Performed by equipment operators Daily cleaning, inspecting, lubricating, bolt tightening; prevents equipment deterioration. 15 min/day Transfers ownership to person running machine

32 Productive Maintenance
Autonomous Maintenance Steps: 1) Thoroughly clean all equipment may take place during plant shutdown

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Autonomous Maintenance Steps: 2) Make FUTURE cleaning easier and faster by: Improving access to equipment Eliminating sources of contamination Establishing standard operating procedures Making sure correct items are on hand (proper lubricants, cleaners, etc…)

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Autonomous Maintenance Steps 3) Basic Training Teach correct procedures, settings, adjustments Teach problem detection Teach problem resolution

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Autonomous Maintenance: Housekeeping Rules 1)Only necessary items at workplace 2) Design locations for everything 3) Keep workplace clean 4) Everyone participates 5) Continuous adherence

36 Productive Maintenance
Productive Maintenance Takes COMMITMENT!

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