TPMVisit Us at Management - Umakant.info
TPMVisit Us at Management - Umakant.info
TPMVisit Us at Management - Umakant.info
ON
for
Customer Enquiry
Marketing
Design of Product
Estimation
Kick of Meeting
Drawing Issued to all
Concerned Dept.
Making of Purchase
Purchase Request
Order
Raw Material
Finish Job Inspection
Inspection
Incoming Material
Receipt/Outbond
Issued to Assembly
Shop
Painting/Stage Testing/Customer
Inspection Inspection
Packing/Packing Insp.
Dispatch
Documentation
1. Definition:
• By reducing no of operation
• By changing the operation sequence
• By reducing no. of parts
• By reducing transportation/Material Movements
• Reducing set up time
• Changing Plant Layout
• Using Proper Jigs & Fixture
• By Outsourcing
• Reducing scrapes
• Reducing Variations In Jobs
• Reducing loading & Unloading time
• Reducing Breakdown Time.
• Eliminating Rework
• Improving cash Flow Rate
• Change in Organisation scheme.
Reviewing the most likely ways that equipment will fail has been a
major concern in reliability-centered maintenance to ensure that
proactive, predictive and preventive maintenance activities during
turnaround could be planned and carried out. So often that
maintenance department will adopt a more cautious approach of
playing safe and relying on the conventional or usual method of
equipment maintenance rather than trying a proven method which has
been tested to be efficient just to avoid any complicated matter arising
from the method.
1. Breakdown Maintenance
This is one of the earliest maintenance program being implemented in
the industry. The approach to maintenance is totally reactive and only
act when the equipment needs to be fixed. This strategy has no
routine maintenance task and also described as no scheduled
maintenance strategy. To rectify the problem, corrective maintenance
is performed onto the equipment. Thus, this activity may consist of
repairing, restoration or replacement of components. The strategy is
to apply the corrective maintenance activity only, which is required to
correct a failure that has occurred or is in the process of occurring.
2. Preventive Maintenance
This is a time-based maintenance strategy where on a predetermined
periodic basis, equipment is taken off-line, opened up and inspected.
Based on visual inspection, repairs are made and the equipment is
then put back on-line. Thus under this equipment maintenance
strategy, replacing, overhauling or remanufacturing an items is done
at a fixed intervals regardless of its condition at the time. Although
this is a well-intended strategy, the process can be very expensive as
typically 95% of the time everything was alright.
3. Predictive Maintenance
Predictive maintenance is a more condition-based approach to
maintenance. The approach is based on measuring of the equipment
condition in order to assess whether an equipment will fail during
some future period, and then taking action to avoid the consequences
of that failures. This is where predictive technologies (i.e. vibration
analysis, infrared thermographs, ultrasonic detection, etc.) are utilized
to determine the condition of an equipment, and to decide on any
necessary repairs. Apart from the predictive technologies, statistical
process control techniques, equipment performance monitoring or
human senses are also adapted to monitor the equipment condition.
This approach is more economically feasible strategy as labors,
materials and production schedules are used much more efficiently.
4. Proactive Maintenance
Unlike the three type of maintenance strategies which has been
discussed earlier, proactive maintenance can be considered as an
another new approach to maintenance strategy. Dissimilar to
preventive maintenance that based on time intervals or predictive
maintenance that based on condition monitoring, proactive
maintenance concentrate on the monitoring and correction of root
causes to equipment failures. The proactive maintenance strategy is
also designed to extend the useful age of the equipment to reach the
wear-out stage by adaptation a high mastery level of operating
precision.
Maintenance
Maintenance Approach Signification
Strategy
Breakdown
Fix-it when broke Large maintenance budget
Maintenance
Maintenance Cost
Concluding Remarks
The goal of maintenance program is also changing and with the rapid
technological development, improvement of equipment and technology
will be one of the key aspects of improved maintenance practiced for
better productivity, effectiveness and profitability.
3M Analysis
This analysis is a set of conditions with respect to machine, material
and method for obtaining a good product. It helps in identifying 3M
standards and checking is possible against these standards. Removing
this variability can some times eliminate Quality Defects in the
product.
Equipment
Case
Date and time Occurred Month/Date/ Hour/Minute Date and Time Work Started Month/Date/ Hour/Minute Date and Time Work Completed Month/Date/ Hour/Minute
Production Code 01 Production Stop 02 Production Non-stop Production Stoppage Time Hours and Minutes
(How repaired, why it occurred and what to be done in future. Describe as much as possible)
Cause/Action/Counter-
measure
Needed/ Not needed KAIZEN Record No. Needed/ Not needed Maintenance Information No.
Initial Effective Maintenance Countermeasure for Failure Rate Cause Analysis Executable Countermeasure Implement Prevention of Recurrence
WHY WHY ANALYSIS
Q. Why-Why Process?
Preventative maintenance
Conclusion:
Q : Did Company learn any lessons implementing TPM?
Manager said, "We learned that training is a key to being successful
with TPM. We did some initial TPM awareness training for the
organization, about one week of training with the operators, and some
for the mechanics. But, looking back we could have had quicker
success if we had done more training." Manager also credits their
success to the support of their management, the union, the hard work
of the people at company, involvement of consultant, and the support
of their customers. "Ultimately this is a people issue and we are lucky
to have the right people involved," he said.
Thinking back about the initial resistance to TPM, TPM Coordinator laughs
and says, "At first a lot of folks here defined TPM as 'Totally Painted
Machines'. Now I can say we all define TPM as 'Taking Pride in our
Machines'."