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

5. Productive Maintenance
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

7. 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%

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.

11. 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

12. 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

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

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

16. 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

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

18. 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?

19. 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

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

21. 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

22. 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

23. 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

24. 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

25. 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

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

27. 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.

28. 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

29. 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

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

31. 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

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

33. 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…)

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

35. 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

36. Productive Maintenance
Productive Maintenance Takes COMMITMENT!