Productive Maintenance Chapter 15

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

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

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

Productive Maintenance Benefits Eliminate Waste Wasted Time Wasted Resources

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

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

How will we accomplish this?

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

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.

Productive Maintenance 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

Productive Maintenance 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

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

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

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

Productive Maintenance 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

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

Productive Maintenance 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?

Productive Maintenance 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

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

Productive Maintenance 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

Productive Maintenance 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

Productive Maintenance 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

Productive Maintenance 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

Productive Maintenance 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

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

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

Productive Maintenance 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

Productive Maintenance 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

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

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

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

Productive Maintenance 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…)

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

Productive Maintenance 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

Productive Maintenance Productive Maintenance Takes COMMITMENT!