Prepared by TPM secretariat, IIL, Dolvi

57
1. Goal:

Planned Maintenance has to focus on preventive actions to eliminate Equipment failures/

breakdowns in order to ensure availability and reliability of Equipments and to minimize
cost of maintenance.

2. Approach:

To realize Maintenance goals there are two classifications of Maintenance measures.

a. Maintenance Activities:
i. To prevent failures.
ii. To fix failures.
b. Improvement Activities:
i. To extend life span of parts
ii. To shorten maintenance time
iii. To avoid maintenance.

3. Maintenance Activities:

As for maintenance activities, there are three elements.

a. Activities to prevent deterioration.
b. Activities to measure deterioration.
c. Activities to restore deterioration.

Overview of the Planned Maintenance activities are shown in page 69a

4. Methodology:

The following step-by-step methodology would help to achieve prevention of

Equipment failures/ breakdowns.
Step – 1 : Support and Guidance of Jishu Hozen Activity.
Step – 2 :Evaluation of Equipment failure / Breakdown status and understand
situation
Step – 3: Reverse Deterioration and correct Weakness.
Step – 4 : Build an Information Management System.
Step – 5: Build a Periodic Maintenance System.
Step – 6 : Build a Predictive Maintenance System.
Step – 7 : Evaluate the Planned Maintenance System.
The activities involved in these steps are briefed below.

Prepared by TPM secretariat, IIL, Dolvi

58
4.1 Step - 1: Support and Guidance of Jishu Hozen Activity:

The detailed flow chart of the activities is shown in page -70

During initial cleaning, step 1 of Jishu Hozen activity, Maintenance personnel need to
participate with Operation division in putting blue tag and yellow tag. During this
activity Maintenance need to educate Operators as to structure of Equipment,
Mechanism, and how to find defects by cleaning and inspection. Also, teach as to how
to develop One Point Lesson.

The Yellow tag removal which requires technical solution is to be attended by

Maintenance personnel. After removal of yellow tag, Maintenance should prepare
yellow tag summary sheet and countermeasures implemented.

Countermeasures against sources, changing hard to access areas to easy to access are
to be done by Maintenance.

In preparing tentative standards of cleaning, inspection and lubrication for operators,

maintenance personnel should extend help.

To extend help to Operators in education and on the job training in JH step 4

To impart training to improve maintenance related technical ability.

4.2 Step - 2 : Evaluation of Equipment Failure Breakdown status and understand

situation.

The detailed flow chart of the activities are shown in page- 71

Collect data on all the failures/ breakdowns, which caused production loss and analyze.
The related documents for the collection of failures/ breakdowns data are Equipment
Logs and Breakdown Sheets from Operation.

Decide what are the equipments to be taken for PM activities using criteria for
evaluation of Equipment Rank. See page -72 for evaluating Equipment Rank.

After understanding the nature of loss and Equipment importance, set target for
Equipment Failure/ Breakdown.

Prepared by TPM secretariat, IIL, Dolvi

59
 Prepare a Plan to carry out the activities to achieve the target.

4.3 Step - 3: Reverse Deterioration and Correct Weaknesses:

In respect of restoring deterioration the participation of Operation Division is

available through Jishu Hozen implementation. The roles of Operation Division are:

a. Doing Cleaning, Inspection, Lubrication and Retightening to bring back the Basic
Condition of the Equipment.

b. Keep operating condition through correct operation handling.

c. Restoration of forced deterioration. Mainly, by an inspection for deteriorating parts

and discovering irregular symptoms.

d. Operation skill including inspection techniques, set up and adjustment of

Equipment to be improved.

On the other hand the roles of Maintenance Division are

a. Jishu Hozen activities of the Operation Division should be technically supported.

b. Assuring restoration of deterioration by Inspection using optimal condition check

sheet.

c. Defects, deterioration and weak points of Design should be found out. Using why -
why analysis countermeasures are to be implemented for the removal of defects and
restoration of condition of parts. See page -74 and 75 for why-why analysis.
Improvements are to made to strengthen the weak points of design. This may be
converted into improvement kaizens. If the kaizen idea warrants design change of
parts, create MP sheet. (Maintenance Prevention Sheet .See Page -76 for MP sheet.

d. Maintenance skill in the above should be improved.

The above four items are major points and they are originally assigned to Maintenance
Division.

4.3.1 In finding out the deteriorations on Equipment during Initial Cleaning, Maintenance
Division needs to participate with Operation Division and help Operators. Then
yellow tag put by Operators are to be removed after analyzing cause and
Prepared by TPM secretariat, IIL, Dolvi
60
 implementing corrective action. Also, the findings through optimal condition check
sheet by Maintenance Division are to be corrected in the same way.

4.3.2 Abolish the environment causing forced deterioration with the help of Operation
Division.

4.3.3 Using breakdown analysis sheet of each Equipment, find is the breakdown natural or
forced and implement measures to prevent breakdowns. If the breakdown is natural
and analysis finding is weak design, improve the design by Kaizen.

4.3.4 From the cause analysis of the breakdown develop skill to forecast problem in each
equipment, forecast problems, arrive at counter measures and implement.

4.3.4.1 MTBF: Mean Time Between Failure - This is an indicator of reliability of

Equipment. This should be high. MTBF = Total available time / No. of
breakdowns.

4.3.4.2 MTTR: Mean Time to Repair - This is an indicator of maintainability of

Equipment. This MTTR span is to be shortened. MTTR = Total down time! No of
breakdown.

4.3.5 Follow TBM and CBM for vital and essential parts of Equipment.

4.3.5.1 TBM - Time Based Maintenance: The maintenance activity to be carried out
based on the schedule prepared based on the manufacturers' recommendation and
past experience. For example if a part is to be changed after a period of two months,
carry out as per schedule. See page for TBM Process.
4.3.5.2 CBM - Condition Based Maintenance: Based on the condition of part decide
whether to change or not. For example bearing replacement in a Spindle
arrangement is based on abnormality symptom i.e. based on the condition of
part and not by time limit. The condition check of parts are detailed in predictive
maintenance in step 6. See page - 79 for CBM Process.

4.4 Step - 4 : Build an Information Management System:

The detailed flow chart of the activities are shown in Page -80.

4.4.1 To start with, prepare Equipment Ledger. Feed Equipment data like model,
specification, capacity, Manufacturer's recommendation, etc. Also, feed the
Equipment history right from installation to till date i.e. the breakdown maintenance
Prepared by TPM secretariat, IIL, Dolvi
61
 report, failure analysis report, preventive maintenance report etc. This is the basic
Maintenance Division's data base. One part of Equipment Maintenance Record is
shown in page -81.

4.4.2 Using Equipment data and Equipment history data arrive at Yearly and Monthly
Preventive Maintenance Plan.

4.4.3 The system failure data management sheet, failure analysis report, failure mode and
effect analysis and equipment maintenance control system are shown in page no 82.

4.4.4 The Equipment spares are to be stocked under three categories such as Vital, Essential
and Desirable. The spares identified thro' optimal condition check and Time Based
Maintenance are to be appropriately categorized as stated above and controlled. The
main objective of this system is to reduce inventory of spares and inventory cost.

4.5 Step - 5 : Build a Periodic Maintenance System:

The detailed flow chart of the activities are shown in page -84.

This is related to time based maintenance of Equipment. From the Equipment

database, preventive maintenance data base, machine manufacturer's recommendation,
past experience, life span of parts and operator's information, arrive at Planned
Maintenance Calendar.

4.5.1 Prepare time based work system flow to carry out the activities. The efficiency of
Time based Maintenance could be felt in reliability of Equipment and cost.

4.5.2 The kaizens related to life span improvement of parts, easy maintainability of parts are
to be arrived at.

4.5.3 Revisit optimal condition check sheet and correct wherever necessary based on
experience.

4.6 Step - 6 : Build a Predictive Maintenance System:

The detailed flow chart of the activities are shown in page -85.

Introduce Equipment Diagnostic Technology. Train maintenance personnel in

handling diagnostic instruments / devices.
Prepared by TPM secretariat, IIL, Dolvi
62
 Equipment Diagnosis Technology consists of various techniques to grasp present
conditions of Equipment and to predict and anticipate the cause of future irregularities
or failures.

The following are the Mechanical related diagnosis techniques.

• Rotary Machine Diagnosis Technique.
• Crack Diagnosis Technique.
• Lubrication Diagnosis Technique.

The following are the Electrical related diagnosis techniques.

• Rotating Electric Machine Diagnosis Technique.

• Control System Diagnosis Technique.
• High Voltage Cable Diagnosis Technique.
• Transformer Diagnosis Technique.

The following are the various diagnosis method.

• Temperature Method.
• Vibration Method.
• Oil Analysis Method.
• Liquid Penetrate Method.
• Dimension Measuring Method.
• Insulation Measuring Method.
• Electric Resistance Method.

Prepare Diagnostic Maintenance Work System "Flow.

• Select area and implement Equipment Diagnostic System in to practice.
• Develop Equipment Diagnosis skill and change TBM parts In to CBM parts. Finally
consolidate CBM.

• Predictive diagnosis and diagnosis method for a specific Equipment are shown in
Annexure-51.

4.7 Step - 7: Evaluate the Planned Maintenance System.

The detailed activities are shown in page -87.

By following step 1 to step 5 the Maintenance Division could have achieved

Prepared by TPM secretariat, IIL, Dolvi
63
 improvement in Reliability and Maintainability of Equipment. Compare the current
results on Breakdown Rate, MTTR, MTBF, Preventive Maintenance Rate,
Maintenance Cost, etc with the target. After comparison, revisit the total system and
strengthen the weak point. Finally, consolidate the Planned Maintenance.

In order to carry out these Maintenance activities a Master Plan is to be prepared.

5 Improvement Activities

5.1 Extending Life Span of Parts

5.1.1 If life of part is short in spite of removal of forced deterioration, the life could be
extended by analyzing the weak points such as 1) Lack of strength, 2) Design/
Construction defect, 3) Processing defect. The weak points of the part are to be
analyzed and to be strengthened. Thus life of part could be extended. The
improvement made on the part to be converted in to MP Sheet.

5.1.2 The parts covered under TBM and CBM of equipment are to be analyzed for life
improvement and maintainability improvement. If, the analysis finding warrants
change of design parameters to remove weak points, do concentrated kaizens and
implement. This comes under corrective maintenance.

5.2 Shortening Maintenance Time

The first and foremost thing required to reduce maintenance time is skill of
Maintenance Personnel. Skill is the power to act rightly and reflexively based on
learnt knowledge. This is to be acquired by all Maintenance operating personnel. It is
necessary to arrange Maintenance skill development programme to all maintenance
personnel. The basis of the development programme is OJT (On Job Training) and
self development. It is important to build an environment in which men try to
learn to deal equipments by themselves. See page - for Maintenance skill training
system. MTTR could be reduced only by skill development.

5.3 Avoiding Maintenance:

In order to achieve 'To avoid Maintenance' zero failure is to be achieved in

Equipments. Zero failure could be achieved by thoroughly practicing the various
activities indicated as above. In respect of this, Maintenance personnel have to
systematically follow:

Prepared by TPM secretariat, IIL, Dolvi

64
• Daily countermeasures to prevent recurrence of failure by true Kaizens.
• Analyze priority parts from MTBF and MTTR viewpoint.
• Improve present maintenance method. After improving inspection methods and repair
procedures prepare maintenance standard.
• Extend life of parts and control weakness. i.e. implement corrective maintenance.
• Upgrade to predictive maintenance structure for efficient checks.
• Conduct Overall Equipment diagnosis for function deterioration type failures.
• Challenge to extreme use of parts to control maintenance cost.

6. Management of Maintenance Cost:

a. Maintenance cost is regarded as an 'expense' from the view point of Accounts

section. Generally this covers repair material cost, repair labor cost, repairs by
subcontractors. However, in order to have control against budget, it should be
categorized as below for effective information for management.

Prepared by TPM secretariat, IIL, Dolvi

65
 • Daily maintenance costs towards labor and material to prevent Equipment
deterioration.
• Equipment inspection costs towards labor and material to determine irregularities or
fitness of Equipment
• As categorized by Maintenance the preventive maintenance cost, the breakdown
maintenance cost and corrective maintenance cost.
• Maintenance material cost such as spare parts, material supplies, Lubricants and tools
which are consumed by Maintenance.
• Cost of contractors who are engaged for repairing Equipments.
• Cost incurred in maintenance of main piping, main wiring, building
• Cost towards electricity.

b. The general points to reduce maintenance cost are given below. This may vary industry to
industry depending on the type of business or Equipment used.

• Review of inspection/check! periodical fixed cycle

o Reduction of Maintenance action Extension of life cycle by extension of the
parts life span.
o Overhaul cycle determined by meeting the shortest cycle utilizing in-house
mechanical maintenance.
o Time based maintenance method and Condition based maintenance method.
• Is too much money spent on lubricant management? If Equipment is in a normal
condition, deterioration and consumption of oil are less.
• Change of subcontractors' work to in-house work. Accumulation of PM technology
and skill of Maintenance personnel.
• Removal of downtime and transportation loss caused by inappropriate repair
management & parts management.
• Efficient improvement of irregularity restoration. Unification of pans, establishment
of accuracy and standard surface of parts and replacement system.
• Review of spare parts. Designed stock level and inventory of spares cost.
• There are some parts which need not be procured at high cost. In terms of function,
such parts can be replaced cheaper ones.
• Effective recycling of unused parts. Internal exchange of information.
• Reduction of resource energy loss. Prevention of leakage and product material
overflow. Prevention of idling
• Removal of Equipment loss Repair of sporadic failure, energy loss until recovery,
yield loss. Defects due to performance-deterioration type failure.

Prepared by TPM secretariat, IIL, Dolvi

66
7. Management of Lubrication

Approximately 40% of Equipment composition is accounted as friction parts. These parts

needs correct lubricant for the following aspects:

• Decrease of friction- in turn reduction of power loss.

• Smoothness of parts movement to carry out operation.
• Prevention of abrasion.
• Prevention of heat generation.
• Cooling action.
• Cleaning of dirt and foreign matter from the friction surface.
• Rust and corrosion proofing:
• Prevention of vibration and noise.
• Others.

Around 40% of Equipment problems are due to lubricant and lubrication method.
Lubrication management is essential to prevent failures, to improve productivity and to
reduce maintenance cost. Lubrication management can be divided into two parts. One part is
material management and the other is technology management.

Material management covers purchasing, acceptance, storage, payment to suppliers and

disposal of used lubricant.

Technical management sets up four principles of lubrication i.e. appropriate oil, appropriate
amount, appropriate method and appropriate timing.

Selection of lubricant. The lubricants are divided into three types.

• Liquid lubricant
• Grease
• Solid lubricant.
Depending on the purpose, lubrication should be selected and applied. For this full
understanding of the characteristics of lubricant and as well as surveying the conditions of
the place of application and actual condition of lubricant.

The appropriate lubricant to be selected considering shape, load, speed, viscosity coefficient,
hardness and roughness of friction surface. oil type. The viscosity coefficient is especially
important in the selection of the appropriate lubricant. See page - for Lubrication inspection
items table.

Prepared by TPM secretariat, IIL, Dolvi

67
Generally in order to evaluate the Planned Maintenance activity, the measurement details are
shown in page -

8. Zero Failures of Priority Equipment:

An efficient Maintenance System is to be established to achieve zero failures on Equipments.

This is possible after implementing the step by step methodology stated in the beginning for
prevention of failures / breakdown. The following steps should be followed further, in order
to achieve Efficient Maintenance System.

To start with, Maintenance Division must select priority Equipment whose downtime causes
great impact on loss reduction in production division. Analyze thoroughly the Equipment,
part by part, to devise measures to prevent recurrence of failures. The steps to be followed
are stated below.

• Select priority parts.

• Improve present maintenance method.
• Prepare maintenance standard
• Life extension and weakness control.
• Efficient checks.
• Overall equipment diagnosis.
• Challenge to extreme use.

Step - 1: Select priority parts:

Based on the experience of Maintenance Staff and past records, select priority parts for
the function of equipment. Some of the selection criteria are given below.

• The parts that will require repair work that is large in man hours and cost.
• The parts that will become trouble work in work planning.
• The parts that will require repair work demanding high skills.
• The parts with poor work efficiency.
• Analyze those parts from the viewpoint of MTBF. Also analyze from MTTR
viewpoint.

Step - 2. Improve maintenance method:

Study, as to, what check and inspection methods are presently being followed for those
parts. Also, study as to what overhaul check and repair procedure are being followed.

Prepared by TPM secretariat, IIL, Dolvi

68
Then analyze those parts from the viewpoint of MTBF and MTTR. Improve and develop
maintenance work method.

Step - 3. Prepare maintenance standard:

After developing maintenance work method, study, set, and change check and inspection
periods. Then, standardize priority work and establish preventive maintenance structure.

Step - 4. Life extension and weakness control:

Analyze inherent life of part. Take actions on improving the life. Consider
countermeasures by FTA diagrams, PM analysis, FMEA and other methods based on
Equipment design conditions. Thus, improve maintenance ease. (This is corrective
maintenance activities)

Step - 5. Efficient checks:

With the improved maintenance work method, implement failure prediction technology.
To the maximum extend possible, to ease the work, follow visual control. In respect of
parts, based on corrective maintenance, change standards and manage spare parts. (This
is upgradation to predictive maintenance structure.)

Step - 6 Overall equipment diagnosis - M-Q analysis (Machine-Quality analysis):

The steps upto Step 5 are mainly for dealing exclusively with function stoppage failures.
The steps from step 6 are for function deterioration failures. Infact, these steps are
Quality Maintenance activities by maintenance division for improving parts to ensure
reliability. As being followed up in Quality Maintenance Pillar, Maintenance division
need to follow up Quality Maintenance features for elimination/reduction of functional
deterioration of parts/equipment.

Step - 7. Challenge to extreme use:

The improvement points made till step 6 are to be incorporated in the equipment
maintenance management system and all related maintenance works are to be eased out.
Also, the improvements must reflect on maintenance cost management.

Prepared by TPM secretariat, IIL, Dolvi

69