Reactive to Proactive Maintenance through LEAN

What is Reactive, Proactive and Lean?

Where do we find these wastes in maintenance processes???

3P: Production Prep Process

What is meant by “TOTAL” Productive Maintenance

Parent, Baby and Doctor!!!

8 A set of activities for restoring equipment to its optimal condition and changing the work environment to maintain those conditions through daily maintenance activities. TPM To identify productivity losses and involve all members of the company in loss elimination programs.

TPM is a Lean tool to optimize the effectiveness of manufacturing equipment and tooling. What is TPM?? 1.Starts with 5S / Visual Factory 2.Builds a comprehensive Downtime Database by cause, frequency, and duration 3.Predicts and prevents downtime by PM system 4.Expands role of Operator as first point of early warning and prevention 5.Develops Professional Maintenance skills

What is 5S

What is FOCUSSED IMPROVEMENT

Visual Controls…

Planned Maintenance!

What is wrong with CORRECTIVE MAINTENANCE?

What do we do in planned maintenance??

Where does it touch boundaries with PREVENTIVE MAINTENANCE

Categorize by equipment, type of breakdown etc. Segmented bar graph for lost time Subcategories for Equip (e.g.) – Hydraulic / pneumatic – Mechanical / lubrication – Electrical / controls – Shot-end components Subcategories for Tooling (e.g.) – Slides – Cores – Inserts – Ejector pins Subcategories for Other (e.g.) – Operator error – Materials Downtime Database

Minimum Downtime Tracking Equip Tools Other Example from Cyanide Plant – Calculation of lost time. Example of HLP Machines

Predictive Maintenance Tools Actual Rate/hr vs. Design or target Rate/hr (or historical normal output) Database – Maintenance history – Statistical probability (frequency & duration) – Downtime between failure Physical prediction of impending failure – NDT – Sound (bearing) – Temperature (cooling water) – Flash (core pins) – Shot monitoring system – SPC on part geometry – Hydraulic pressure (ejector pins) – Spindle loads (amps) – Fluids / Lubrication analysis (milipore) – Vibration Signature Analysis

32 Breakdowns & Defects Can Be Divided Into 2 Loss Categories 2. Chronic Loss: 1. Sporadic Loss: Defects suddenly occur, or a piece of equipment suddenly stops. The root cause is usually easy to locate. This type of loss does not occur suddenly. There is usually more than one type of cause to the loss, which makes the root cause difficult to locate. How would you deal with either of these types???

33 Why Should A High Priority Be Placed On Slight Defects? Stop the snowball effect of accumulating defects. To get to the root cause. Slight defects will develop into critical defects. Forced deterioration will shorten the life span of the equipment.

34 2 Types Of Equipment Deterioration Natural Deterioration: Physical wear that occurs even though the equipment is used and maintained properly. Forced Deterioration: Natural deterioration that is increased from negligence on our part, such as lack of oiling, checking, repairing, etc. How would you deal with either of these types???

This leads us to the concept of EARLY MANAGEMENT

36 Rules For Zero Failure Ü Discover latent defects to prevent failures “Failure” is only the tip of the iceberg FAILURE LATENT DEFECTS Dust, soiling, adhesion of raw materials. Abrasion, backlash, looseness, leaks Corrosion, deformation, flaws, cracks Temperature, vibration, sound, and other errors

39 Levels Of Skills Level 0 Level 1 Level 2 Level 3 Level 4 Do Not Know Know The Theory Can Do To Some Degree Can Do With Confidence Can Teach To Others Lack Of Knowledge Lack Of Training Learned By Doing Knows Extremely Well

40 Ability Needed From Operators Ü Ability To Find & Improve Equipment Problems Ü Understanding Of Equipment Functions Ü Understand The Relation Between Equipment & Quality Ü Can Replace Consumable Parts Ü Good Team Member

41 Ability Needed From Maintenance Group Ü Can Teach The Proper Operation & Daily Maintenance of Equipment Ü Judge If Equipment Is Operating Normally Or Abnormally Ü Respond To An Abnormal Condition, Select, & Implement A Timely Repair Ü Technical Skills To Diagnose Equipment & Prevent Breakdowns

Your Role as MAINTENANCE TEAM MEMBERS

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Analyse how equipment contributes to quality defects and maintain them out Example of HLP Machine

CONCLUSION through discussion How do you think today’s discussion can lead us from Reactive to Proactive Maintenance???