Module: TPM Slide Verbal Photo Explain the key objectives:-

Module: TPM Slide Verbal Photo Explain the key objectives:-
It is not a time and motion study It is a method of highlighting waste within the set-up process. It is a means of working smarter & safer Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

To show Best Practice with Airbus UK and the outside world
Aims and Objectives Target Audience : Engineering, Maintenance, Facilities, Procurement, Operations. Purpose of Module : To understand & implement the techniques of effective maintenance to minimise Life Cycle Cost. Aims & Objectives : Relate to TPM/OEE/Autonomous Maintenance Planned Maintenance Preventative Maintenance Predictive Maintenance Design of effective maintenance strategy Understand how to work with historical analysis To show Best Practice with Airbus UK and the outside world Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Contents Introduction TPM Overview Effective Maintenance Overview
Planned Maintenance Preventative Maintenance Predictive Maintenance Breakdown Maintenance Effective Equipment Design Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Total Productive Maintenance
OVERVIEW Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

TPM What is Total Productive Maintenance (TPM)? Continuous Improvement
Improvement Activities Planned Maintenance Autonomous Maintenance Education & Training Maintenance Prevention Continuous Improvement Systematic Elimination of Waste TPM The widely accepted pillars of TPM - - Improvement Activities (embedded in all TPM key drivers in APS) - Planned Maintenance (covered in Effective Maintenance in APS) - Autonomous Maintenance - Education & Training - Maintenance Prevention All supported on a firm foundation of Continuous Improvement and the Systematic Elimination of Waste. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

What is Total Productive Maintenance (TPM)?
A system of maintenance covering the entire life of the equipment and the total human resource. TPM is a tried and tested way of eliminating waste, saving money and making factories better places to work. It gives operators the knowledge and confidence to manage their own machines. TPM is a long term process to increase skills, raise efficiency and achieve zero losses. TPM can be the foundation for improvement for an entire production process. It is not just another maintenance program, it requires co-operation at all levels and function within the business. Team activity is crucial in both the development and continued success of TPM. It means breaking down traditional attitudes to specialist roles and the establishing of an “up-skilling” program for operators and maintainers. TPM means – - Building and improving equipment so that it won’t breakdown, produce defects or have minor stoppages. - Training operators to be capable of detecting equipment defects, implementing inspection and lubrication for maintenance. - A work place where equipment is easy to use, work can be done both easily and safely, and with a high productivity. Maintenance of normal conditions / Early discovery of abnormalities / Prompt response Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

What are the benefits of TPM?
TPM refuses to accept that machine inevitably fail. TPM reduces the total life-cycle costs of equipment. TPM simply reminds us that every time a machine fails, something could have been done to prevent it. Gradually the operator’s become maintainers. Gradually the maintainers become improvers. TPM develops the five senses, as well as technical skills. Zero Breakdowns – Zero Accidents – Zero Defects. Philosophies that could and should be considered across all aspects of the business, that: “failure is not inevitable and something could have been done to prevent it”. WHAT WILL STOP IT HAPPENING AGAIN? TPM helps break down barriers to best practice by removing specialisation. Maintainers benefit from “up-skilling” of operators as they are able to focus attention on improving preventative measures and removing waste from the life-cycle of equipment. Breakdowns may be sudden but the signs are often there well before the machine finally ceases to run, i.e. unusual sounds, vibrations, etc. Maintenance of normal conditions / Early discovery of abnormalities / Prompt response Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Loss Elimination through TPM?
Equipment Six Big Losses Breakdowns 1 Available time Setup / adjustment 2 Available operating time Idling / minor stoppages 3 Actual operating time Speed 4 Animation - Activate randomly as you talk through. TPM will focus on the 6 big losses that impact Availability, Productivity and Quality. Breakdowns and Set Ups reduce the “Available Time” that operators have to add value during “Operating Time”. Further stoppages and factors which effect the most effective use of that “Operating Time”, are Idling, Minor Stoppages and Speed Losses, i.e. tool breakages, swarf clearance (<10 mins) and the effect of equipment not running to optimum speeds. This “Actual Operating Time” is then finally lessened by the impact of Defects (Rework) and Start Up Losses (both in quality and delays achieving optimum conditions). Effective operating time Defects in process and rework 5 Start up losses 6 Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

What is Effective Maintenance?
PLANNED MAINTENANCE “ The scheduling of maintenance activities on a time based or usage basis regardless of the current performance levels of the equipment” PREVENTATIVE MAINTENANCE “ A systematic approach to eliminate catastrophic failure/breakdowns through regular care and attention, early diagnosis and rectification” PREDICTIVE MAINTENANCE “ A systematic approach utilising history and equipment condition monitoring to predict and prevent catastrophic failure/breakdowns ” It is not :- “Repairing equipment as quickly and efficiently as possible when it breakdowns“ It is :- “Minimising the chances of equipment ever breaking down, ensure it runs as effectively as possible and repairing it as quickly and efficiently as possible if it does “ All the activities within Effective Maintenance systems require close working partnerships with operations. We must not accept the arguments that:- “Its running all right at the moment, lets leave it” “We can’t spare the time for planned maintenance”, etc. Maintenance of normal conditions / Early discovery of abnormalities / Prompt response Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

What is Effective Maintenance?
BREAKDOWN MAINTENANCE “ When all else fails ensuring that equipment availability is achieved in the shortest possible time whilst eliminating root cause faults with sustainable repairs” EFFECTIVE EQUIPMENT DESIGN “ A systematic approach to equipment design which maximises equipment availability, minimises life cycle costs and eliminates waste” Machines will inevitably still breakdown as a TPM system strives towards maturity, when they do fail we must not revert to the “Quick Fix”. By all means instigate immediate customer protection, but root cause investigation and elimination must be the goal. Assess current production requirements and consider value added planned maintenance in parallel with breakdown repairs. Why wait until equipment is in service before we consider how to maximise its availability. Ensure equipment is designed with maintainability and reliability as the watch words. Maintenance of normal conditions / Early discovery of abnormalities / Prompt response Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

What is Autonomous Maintenance?
An operator skills development programme. Allows problems to be identified and solved quickly. Stops accelerated deterioration of plant and equipment. An approach to stop deterioration related failures. Stabilises equipment conditions (standards). Develop training materials on how to run, operate & maintain equipment. The primary way in which production departments play a part in TPM is through Autonomous Maintenance. Operators systematically trained in a step-by-step process for cleaning, checking and making minor adjustments on the equipment they work with. Bring operators and maintainers together for a common goal. Early detection and treatment of abnormal conditions. Up skill program for operators. NOT:- “I run, you fix” Assess current production requirements and consider value added planned maintenance in parallel with breakdown repairs. Maintenance of normal conditions / Early discovery of abnormalities / Prompt response Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

What is Overall Equipment Effectiveness (OEE)?
Overall Equipment Effectiveness (OEE) is a total measure of performance that relates the availability of the process to the productivity and quality. OEE is the Key Performance Indicator (KPI) for TPM. OEE will measure the impact of change on a process caused by eliminating process, or equipment losses. A World Class Company should achieve 85% OEE on key equipment (typical operation between 40 to 60%). If you were told that equipment effectiveness in your department was 95% you might reasonably assume that the equipment was running efficiently and effectively How is that measured ? What does it take account of ? What if the equipment was 95% effective and this meant it ran for 95% of the time? Still impressed ? Is it still a good measure ? What if it ran for 95% of the time but had 50% scrap ? TPM is a shift from traditional accounting measures of performance. Still impressed? I thought not! OEE is the KPI for TPM that combines availability, productivity and quality to give a total measure of a machines performance. Provides the focus for eliminating waste through reducing losses. Maintenance of normal conditions / Early discovery of abnormalities / Prompt response Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

What is Quick Changeover?
Quick Changeover is a method of analysing and reducing the time needed to change a process from producing one good part to producing the next good part part. It is a driver for standardisation. It is one of the 6 Big Losses. Quick changeovers are an enabler for flow. Often referred to as “Single Minute Exchange of Die” (SMED). REDUCE - COMBINE - ELIMINATE Often too much emphasis is placed on reducing machining times when the impact of long changeovers is much more of an impact. Changeovers outside TAKT, hinder flow. Adjustments tend to take up the majority of the time during a changeover – Necessary and Unnecessary. Divide work content into “Internal” and “External” activities – Internal : Those activities that can only be done whilst the machine is not producing. External: Those activities that can be done whilst the machine is cycling. Maintenance of normal conditions / Early discovery of abnormalities / Prompt response Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

What will TPM do for our business?
IMPROVE HUMAN RESOURCES IMPROVE PLANT AND EQUIPMENT IMPROVE CORPORATE CULTURE Through educating and developing the workforce in Lean Manufacturing - We can improve plant and equipment - The culmination of both these factors will lead to an improvement corporate culture. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Effective Maintenance
INFORMATION Planned Maintenance Effective Equipment Design Preventative Maintenance Predictive Maintenance Breakdown Maintenance 5 Key Elements covered - Planned Maintenance Preventative Maintenance Predictive Maintenance Breakdown Maintenance Effective Equipment Design Supported throughout by - Training Information Without the support of Autonomous Maintenance, maintainers will continue to be dragged into repeating, minor repairs and adjustment. TRAINING AUTONOMOUS MAINTENANCE Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Is not :- “ Repairing equipment as quickly and efficiently as possible when it breakdowns“ Is :- “ Zero Breakdowns” ASK - What does everyone believe Effective Maintenance is? To reveal Good maintenance practices are all about minimising the chances of equipment ever breaking down in the first place. Good maintenance is also about maximising equipment effectiveness, I.e. making sure that when it is running it can be run to optimum conditions. This is an ultimate aim and will not be achieved in a short space of time Extra Info Available Prepared Flip chart Photo Training Matl. Flip Chart Verbal Slide Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Introducing an Effective Maintenance system is not a “quick fix”. Effective Maintenance should involve all areas of the organisation. Information is key. Operator and Maintainer training Up-skill Maintenance to be trainers and equipment improvers Up-skill Operators to be equipment maintainers Total Productive Maintenance embodies the philosophy of all jobs functions working together to maintain equipment in optimum condition - Operators with day to day checks and basic maintainance - Maintainers understanding and working with production - T/L’s and Planning scheduling to allow for Planned Maintenance Information in the form of data collection from the shop floor, maintenance systems and feedback from operators (5 senses - Sight, Sound, etc..) Key is PDCA - Ensure that systems are flexible, continually monitored and modified to reflect the live situation. Act A P Plan Check C D Do Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Autonomous Maintenance
Definition:- conditions and halting further deterioration” “The partnership of Production and Maintenance departments to accomplish a common goal, stabilising equipment conditions and halting further deterioration” Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Autonomous Maintenance
Operator skills development programme. Allow problems to be identified and solved quickly. Stop accelerated deterioration of plant and equipment. An approach to stop deterioration related failures. Stabilise equipment conditions (standards). Develop training materials on how to run, operate & maintain equipment. Run through the slide Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance INFORMATION TRAINING AUTONOMOUS MAINTENANCE
Effective Equipment Design Preventative Maintenance Predictive Maintenance Breakdown Maintenance ASK - What is Planned Maintenance? TRAINING AUTONOMOUS MAINTENANCE Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance Definition:- “The scheduling of maintenance activities on a time based or usage basis regardless of the current performance levels of the equipment” Emphasise that Planned Maintenance is not only time based, i.e. every 6 months regardless of activity. Could be based on number of cycles (if recorded) or hours in use. Use the analogy of the car, I.e. 12 months or 10,000 miles whichever is sooner. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance Planned Maintenance as part of an Effective Maintenance system takes time and to be effective has to be “a way of life”. Planned Maintenance can make or break the relationship between production and maintenance functions. Partnership is the key. The schedule and time required should be both sympathetic to production needs and be effective. Key elements should be Lubrication Control and Spare Parts Management. Planned Maintenance is not the latest initiative that can be put in place, walked away from and expected to yield instant results. The balance between time given over by production to allow for planned activities and the time required to achieve zero breakdowns, is an important factor as production will only see benefits over time. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance No. of Breakdowns Time Slide Verbal Flip Chart
Autonomous Maintenance Planned Checking & Replacement Factory Wide PM System No. of Breakdowns Predictive Maintenance Time scales will vary but 3 years + should not be unexpected Zero Breakdown Time Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance STEPS TO INTRODUCTION
Evaluation of equipment and knowledge of existing conditions. Restore equipment condition and improve weaknesses. Creating an information management system. Creating and maintaining a Planned Maintenance system. Run through slide Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

EVALUATION OF EQUIPMENT & KNOWLEDGE OF EXISTING CONDITIONS
Planned Maintenance EVALUATION OF EQUIPMENT & KNOWLEDGE OF EXISTING CONDITIONS Identify critical machines - Bottlenecks. Existing machine maintenance records? Combine with Autonomous Maintenance activities. Criticality Assessment. Which machines are on the critical path? Which machines that when broken down will instantly impact on lead time? Where is all your inventory sat in front of? It makes sense to introduce planned systems on to the most critcal machines first. What records do maintenance and production currently hold on lost time, specific breakdown/repair details? If Autonomous Maintenance previously introduced then utilise system otherwise conduct as combined activity We will go into more depth on - Criticality assessment Initial equipment survey OEE data Initial equipment survey. Existing Overall Equipment Effectiveness (OEE) data. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

CRITICALITY ASSESSMENT
Planned Maintenance CRITICALITY ASSESSMENT Environment Cost Total EQUIPMENT DESCRIPTION No Type: Machine: Date: Availability Performance Quality Reliability Maintainability Safety Rank The next 3 sheets indicate the key elements that should be looked for on an “Initial Equipment Survey”. The Criticality Survey is important in so much that having identified bottle-neck machines, there are potential bottle-neck components of a machine, I.e. those which will have the biggest effect on the process should they fail. We will use these and the proforma supplied to conduct a survey on:- PREVIOUSLY AGREED MACHINE in PREVIOUSLY AGREED AREA Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

CRITICALITY ASSESSMENT
Planned Maintenance CRITICALITY ASSESSMENT AVAILABILITY If this failed what would be the impact on running, set-up or adjustment. PERFORMANCE Impact on the cycle time or processing capacity. QUALITY Impact on start up or process. RELIABILITY Impact of this components failure rate. MAINTAINABILITY Ease of maintenance. SAFETY Impact if this failed or was in poor condition. ENVIRONMENT Impact on the environment. COST Impact if failed / cost to the business. By rating each of these elements from 1 to 10, against particular components of a piece of equipment the most critical parts will be identified. Use the manufacturers guidelines, historical data and existing knowledge. This will allow all Effective Maintenance and Autonomous Maintenance activities to be scheduled and weighted correctly. This will allow the spares stocking policy to be planned. This will allow the initial equipment survey and refurbishment to be correctly focused. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

INITIAL EQUIPMENT SURVEY
Planned Maintenance INITIAL EQUIPMENT SURVEY AREA CHECK FOR Damage, dirt, dust, excess oil, splatter and foreign matter. Unnecessary objects on machine. Broken parts, loose or missing nuts, bolts etc. Wear and play of machine. Leaks of oil, air, gas, steam. Indicator lamps not working. Dirt, dust, sludge. Proper lubrication levels. Lubricating devices capped? All lubrication pipes clean with no leaks. Are lubrication levels clearly visible? Name plates and labels are clean and visible. Safety shields are free from dirt, dust & fog. Are pipe routings organised around machine? Check floor condition for rubbish & parts. Are good parts, rejects, scrap material clearly segregated. Check safety devices for damage, malfunctioning or missing parts. Are there any obvious safety hazards or violations. 1. Main body of equipment 2. Ancillary Equipment 3. Lubrication 4. Housekeeping around machine 5. Safety The Initial Equipment Survey is used to determine the current state of the equipment should focus on these key elements. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance INITIAL EQUIPMENT SURVEY CLEAN, CHECK & TAG Operator involvement with maintenance. Operators to “Tag” all elements of the equipment that they believe require improvement. Description of fault and effect on each tag (can be used in conjunction with a machine map). Maintenance to list and answer all tags, i.e. counter-measure and time-scales or reasons for not undertaking. An additional method for focusing attention on equipment issues prior to the commencement of a Planned Maintenance system, is tagging. Good tool for involving operators. Poor tool if the commitment is not given to rectify problems, I.e. tags remaining after 3 months are not very motivating! If concerns are a bridge too far or after investigation they are found not to be the root cause, ensure that this is communicated - ALL tags must be answered. Display timing plan for tag removal clearly for production & maintenance functions. Involve production in improvement activities if practical, even if its only in replacement items such as handles, i.e. what type, etc. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance INITIAL EQUIPMENT SURVEY Tag 1 Tag 2 Tag 3 Tag 4 Tag 5 Tag 6 Tag 7 Tag 8 Tag 9 MACHINE MAPPING Group exercise. Lead by an experienced engineer/maintainer. Use in conjunction with “Tags”. Explain each of the tips to ensure that the session runs effectively. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

INITIAL EQUIPMENT SURVEY Clean, Check & Tag Issues Register
Planned Maintenance INITIAL EQUIPMENT SURVEY Clean, Check & Tag Issues Register Example of the proforma we are going to use to conduct a survey on a critical piece of equipment. Using various codes and classifications we will identify the types of issues that will have to be addressed in the initial stages of a Planned Maintenance system. This should be completed with operators and would also form part of the Autonomous Maintenance activities Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance INITIAL EQUIPMENT SURVEY CONCERN / FAULT ANALYSIS CODE CLASS E = ELECTRICAL M = MECHANICAL L = LUBRICATION H = HYDRAULIC W = WATER P = PNEUMATIC 1 = BROKEN 2 = MISSING 3 = DIRTY 4 = WORN 5 = LEAKING 6 = POOR DESIGN 7 = DIFFICULT TO CLEAN Using a simple matrix a picture can be built up of the most frequently occuring issues and the types of disciplines that might be involved to rectify them, I.e. resource allocation. HAND OUT CHECK SHEETS GO DOWN TO THE FLOOR AND SURVEY CHOSEN MACHINE On returning compare findings on the flip chart. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Animation - Activate randomly as you talk through.
Planned Maintenance OEE AND THE 6 BIG LOSSES Equipment Six Big Losses Breakdowns 1 Available time Setup / adjustment 2 Available operating time Idling / minor stoppages 3 Actual operating time Speed 4 Animation - Activate randomly as you talk through. Collectively these key waste elements which effect Availability, Productivity and Quality, are known as the “6 Big Losses”. OEE data that may have been collected should focus on these 6 Big Losses, the root causes of which may lead to maintenance issue. Clearly “Breakdowns” is directly attributable to maintenance (although they could be through operator error) but all the other losses may have their root cause in the condition of the equipment ASK FOR EXAMPLES , i.e. SET UP - worn threads, broken handles, dirt START UP - Quality defects from cold machines Effective operating time Defects in process and rework 5 Start up losses 6 Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

RESTORE EQUIPMENT CONDTION AND IMPROVE WEAKNESSES
Planned Maintenance RESTORE EQUIPMENT CONDTION AND IMPROVE WEAKNESSES Through the evaluation of the equipment, initial survey and tagging exercise, return equipment to an improved standard. Define the standard and maintain it. Without undertaking initial improvement planned, preventative and autonomous maintenance activities will be less effective. Changes to machine conditions will not be clear Operators time will be wasted Planned Maintenance will take longer The standard should be clearly defined, i.e. approved spares, photos of cleanliness, clearly marked indicators, clearly marked lubrication points (with lube type identified), etc. Regular audits put in place (as part of Planned Maintenance activity). Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance RESTORE EQUIPMENT CONDTION AND IMPROVE WEAKNESSES
Set and maintain standards Now you can see any problems easily! Look at my shiny machine Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

CREATING AN INFORMATION MANAGEMENT SYSTEM
Planned Maintenance CREATING AN INFORMATION MANAGEMENT SYSTEM Without information an effective maintenance system cannot function. Data is gathered to measure and improve performance. OEE is the key performance indicator for Effective Maintenance. Information should be gathered from :- OEE data collection (Operators) Autonomous Maintenance activities (Operators) Planned Maintenance Activities (Maintenance) Predictive Maintenance (Maintenance) Preventative Maintenance (Maintenance) Breakdowns (Maintenance) Run through slide Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

CREATING AND MAINTAINING A PERIODIC MAINTENANCE SYSTEM
Planned Maintenance CREATING AND MAINTAINING A PERIODIC MAINTENANCE SYSTEM CREATING (Plan/Do) Planned Maintenance should be mostly inspection - identify parts for immediate or future replacement, etc. Ensure timings for tasks to the schedule are realistic (buying off with production). Single Point Lessons (SPL) and training to support them. Ensure the schedule is visible to both Production and Maintenance. Do not plan to strip machines down in to little bits! Effective planned maintenance doesn’t have to be a complete refurbishment. By ensuring that the activities are targeted correctly and an initial machine standard has been set, most of the activities should be inspection. Do not replace something just because it will wear out before the next PM activity or spares/consumable costs will rocket. Us the criticality assessment, ensure spares will be available and add to a clearly defined task list. Do not waste production time by planning to allow for too much or too little time for an activity, i.e. production must be able to schedule accurately. Maintainers should work to standard methods as much as production should do. Use clear SPL format -photos/pictures, simple step by step instructions. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance Activities
Date: Items to be Checked No. 1 2 3 4 5 6 7 8 9 10 11 14 12 13 15 Period 3 mth Hydraulic Pressure M/c : Activity SPL 16 17 18 Setting 8-10 PSI 6 mth Replace - Work head Drive Belt 123-4 The PM schedule may have tasks with different periods of checking. It may refer to SPL’s for activities which require a more detailed explanation. However, don’t produce SPL’s for minor tasks can be summed up in a sentence! Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

CREATING AND MAINTAINING A PERIODIC MAINTENANCE SYSTEM
Planned Maintenance CREATING AND MAINTAINING A PERIODIC MAINTENANCE SYSTEM MAINTAINING (Check/Act) Check breakdown frequency between Planned Maintenance and adjust schedule and/or content accordingly. Check the results of Planned Maintenance and if items are continuously OK or always need replacing, adjust frequency. Always look to reduce time for a Planned Maintenance activity, identify items that can be checked in-process. Check information gained from OEE data collection. Maximise equipment availability through efficient PM activities, I.e. reducing breakdowns v reducing time for PM activity. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance INTRODUCING Choose Model M/C in each Area Develop Full PM Frequency Assign Duties Data Collection Predictive Corrective Lubrication Schedule Spare Parts Gather Accurate Data Breakdowns Time Between Failures Process Capability Yield Downtime Capacities Restore / Improve Weaknesses Monitor & Display Results Implement on Model M/c Horizontal Development Continue To Check and Act Suggested steps in the introduction process for PM. Gather accurate data Restore / Improve Weaknesses Develop Planned Maintenance (PM) PDCA and roll out to other machines Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance LUBRICATION CONTROL
A frequently overlooked element which is a contributing factor in 70% of all hydraulic system failures. Should include activities across all disciplines. Minimising cost through rationalisation. Lubrication beyond scope of operators (as part of Autonomous Maintenance), i.e. expensive hydraulic oil. Does it need replacing? Analyse the condition, what does it tell you about the m/c? What is in it? Consider filters. Frequency of change? Level of filtration? Lubrication control should be about minimising waste - lubricant losses, operator/maintainer time and equipment lost time. Ensure the lubricant is fit for purpose and rationalise where possible. Ensure that systems for maintaining levels include - Clear Indicators Clear lubrication points (with lube details at the point of use) Clean machines and surrounding areas for ease of detection Trends, i.e. increased or decreased usage Spill free containers Further steps include analysing the oil content for contaminants and for condition monitoring, I.e. if there is significant metal content this could indicate increased wear. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

LUBRICATION CONTROL - Example
Planned Maintenance LUBRICATION CONTROL - Example 4 POINTS FOR LUBRICATION CHECKS Change Oil after 2.0 point degradation...... 3.5 3.0 2.5 2.0 1.5 1.0 0.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 Do not just change oil simply on a periodic basis, this will lead to unnecessary costs Understand the deterioration of oil and the tell tale characteritics Improve filtration levels if contaminants increase but also tackle the root causes Original Standard Change at this level Check quantity of Oil Check quality of Oil Do not mix oils Avoid contamination Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Planned Maintenance LUBRICATION CONTROL BENEFITS
Reduced friction > reduced wear > extends equipment life. Reduces accidents. Maintains accuracy. Maintains optimum process conditions. Reduces waste. A simple system can save both time and money. The system must be suitable for both operators and maintainers Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

SPARE PARTS MANAGEMENT Scrap - Strip for spares, etc.
Planned Maintenance SPARE PARTS MANAGEMENT Balance stock costs v disruption v achievable delivery. Consumable (wear parts) and Non-consumable. Modular Parts - easy to replace elements. Clearly identified condition of spares, i.e. anything taken off machines should be tagged (visual - red / amber / green) Another simple way of reducing waste and saving money Ensure that the balance is right, i.e. do not over-stock, ensure that stocks suit the requirements Develop supplier relationships to allow stock to be held by distributors for JIT delivery Use clear visual management techniques for inventory management, i.e.foot prints and stock level indictaors Minimise on machine time by utilising modular components as much as is practical, i.e. if replacing a single part in a unit takes 3 days but replacing the unit takes 1 hour - weigh up the risk v benefits Ensure all parts are clearly labelled & their condition known Scrap - Strip for spares, etc. Repair Required Ready to fit Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Preventative Maintenance
INFORMATION Planned Maintenance Effective Equipment Design Preventative Maintenance Preventative Maintenance Predictive Maintenance Breakdown Maintenance ASK - What do you understand by Preventative Maintenance ? TRAINING AUTONOMOUS MAINTENANCE Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Definition:- “A systematic approach to eliminate catastrophic failure/breakdowns through regular care and attention, early diagnosis and rectification” Get the problem before it gets you! Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

ANALOGY Preventative Medicine Daily Health Care Regular Check Ups Early Treatment Preventive Repairs Daily Maintenance (Clean/Lubricate) Inspection Diagnosis Preventative Maintenance Discuss what preventative medicine can mean (flip chart) Eg. the daily checks, regular physicals/health checks and, therefore, early diagnosis/treatment. The same can be said exactly for Preventative Maintenance. Eg. the daily checks, Inspection Diagnosis and Preventative repairs Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Establish where abnormalities will occur without disassembling the equipment. Permits quality checks of repairs already made to overhauled equipment. Permit estimation of repair periods. Reduce maintenance costs by eliminating periodic overhauls. Prevent Accelerated Deterioration. Takes over where Autonomous Maintenance finishes, i.e. the operators regular checks will be a balance of how much they can/should be up-skilled and the time away from the process. Preventative Maintenance will include regular checks and machine monitoring Using the Planned Maintenance Criticality Assessment, the key machine elements will be known and targeted accordingly (including the bits that can’t be seen - understand what the effect will be if a component is failing) Pay particular attention to repairs made, i.e. potential cause of further failure, review after 1 day, 1 week, 1 month, etc. Feedback in to Planned Maintenance schedules Will discuss Prevent Accelerated Deterioration and Maintain Operating Conditions further. Maintain Operating Conditions. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

PREVENT ACCELERATED DETERIORATION Deterioration accelerated by neglect. Interface with Autonomous Maintenance. Daily / weekly check lists. Single Point Lessons (SPL). Simple, regular checks, re-fills and repairs which maintain the equipment to a standard. Clear interface with Autonomous Maintenance, i.e. common check sheets with tasks identified against specific roles. If a task contains a number of elements and pre-requisites ensure that a standard exists in the form of an SPL - clear, concise and easy to follow Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Check no. 1 Preventative Maintenance Check Sheet. Date: Machine: Activity : Freq. Process: Proforma which fits with the Autonomous Maintenance sheets. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

MAINTAIN OPERATING CONDITIONS Equipment “straining” to operate beyond its normal range because correct conditions not maintained. Ensure out of specification conditions are clearly visual or audible, i.e. red zones, level markers, buzzers, etc. Ensure that optimum operating conditions are communicated and clearly indicated. It is important not just to indicate over specification conditions, i.e. too fast or too hot, etc. Any delay in reacting to out of specification conditions could lead to defects, machine damage, increased cycle times, therefore, ensure that deviation is as clearly indicated as possible. Not occurrences of out of specification conditions, i.e. date, times, part number being worked on, to enable links to be made if necessary Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Predictive Maintenance
INFORMATION Planned Maintenance Effective Equipment Design Preventative Maintenance Predictive Maintenance Predictive Maintenance Breakdown Maintenance ASK - What is meant by Predictive Maintenance ? TRAINING AUTONOMOUS MAINTENANCE Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Definition:- “A systematic approach utilising history and equipment condition monitoring to predict catastrophic failure/breakdowns ” “A systematic approach utilising history and equipment condition monitoring to predict and prevent catastrophic failure/breakdowns” Original definition displayed ASK - What is wrong with this statement? To display updated definition Must not be just about understanding when something is about to fail, but ensuring that it doesn’t, i.e. the links with Preventative Maintenance Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Sophisticated. Requires Planned and Preventative Maintenance systems in place. Identify point at which critical part fails. Common method is simply time or frequency based, i.e. no. of rev’s, no. of hours in service, etc. More sophisticated methods are condition based, i.e. temp. of oil, condition of oil, speed of operation. Links with Autonomous Maintenance, i.e. basic predictions based on visual and audible indications. Not to be entered into lightly as a poor system with inaccurate information will waste time and money, i.e. parts will be replaced unnecessarily. Don’t underestimate the most basic form of Predictive Maintenance - the operator on the machine, I.e. 5 senses - sight, sounds, touch, smell and taste (hopefully that should be used too much!) THE OPERATORS IS THE BEST EARLY WARNING SYSTEM - See Autonomous Maintenance Pack Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

WHY? Worth stating again that Predictive Maintenance is a means to an end and should be used to understand failure and the root causes of it. Predictive Maintenance should not be just a passive activity. Root cause problem solving - reduction or elimination. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Breakdown Maintenance
INFORMATION Planned Maintenance Effective Equipment Design Preventative Maintenance Predictive Maintenance Breakdown Maintenance Breakdown Maintenance TRAINING AUTONOMOUS MAINTENANCE Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Definition:- “When all else fails ensuring that equipment availability is achieved in the shortest possible time whilst eliminating root cause faults with sustainable repairs” If all the other elements of Effective Maintenance are not 100% effective then failure will still occur and must be handled as efficiently as possible. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Take repair work beyond quick-fix measures. Always seek the root cause. Historical data. Single Point Lessons (SPL). Record repair work in sufficient detail. Breakdown repair must ultimately be based on root cause rectification, I.e. a repair may be made to give availability in the shortest possible time but if that wastes more time in the long run……. If immediate root cause rectification cannot be achieved then a time for repair must be agreed and adhered to, i.e. it’s very easy for production and maintenance to keep waiting until the temporary repair fails - THIS MUST NOT BE ALLOWED TO HAPPEN Historical data - don’t re-invent the wheel! If a fault has occurred previously how was it cured and why has it failed again? We will now go into more detail on - SPL’s Recording repair work.. Problem solving Problem solving techniques. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

SINGLE POINT LESSON (SPL) - Example Gauge needs to read between red markers within green zone. Single Point Lessons must be quick reminders to help embed basic knowledge and understanding. They are helpful as reference about particular aspects of a task. The maintainers who will use and be trained against the SPL must aid in creating it. Should be signed and agreed by team leaders. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

RECORD REPAIR WORK IN SUFFICIENT DETAIL Lost Time (pareto, OEE) Response time, On/Off Type of repair (mechanical / electrical) Spares Used (spare management) Description, part numbers, reason for failure Cause/Effect What the maintainer believes Conditions Conditions on equipment when it failed Without detailed information about maintenance activities the system will never improve. Only by completing the PDCA circle by continually monitoring and acting on data received will an improvement be seen. Data will influence - Planned / Preventative Maintenance Activities Design / Rebuild of machines Content of Autonomous Maintenance Spares used (supplier, stocks held, etc.) Root cause analysis Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Big problems deserve attention Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

PROBLEM SOLVING TECHNIQUES 5 Why’s. Pareto. Cause & Effect. Brainstorming - at the machine. Include operators - man/machine interface is critical. For more information consult the Problem Solving Training Pack Key element is involvement of the operators - you can’t fix a problem unless you are in possession of all the facts. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Effective Equipment Design
INFORMATION Planned Maintenance Effective Equipment Design Effective Equipment Design Preventative Maintenance Predictive Maintenance Breakdown Maintenance ASK - What do we mean by Effective Equipment Design? TRAINING AUTONOMOUS MAINTENANCE Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Definition:- “A systematic approach to equipment design which maximises equipment availability, minimises life cycle costs and eliminates waste” By ensuring that equipment is designed in a way that its reliability and maintainability are maximised, all the other maintenance functions become easier. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Establish design goals for new equipment. Incorporate TPM improvement activities. Involve the customer and suppliers. Use information derived from OEE data collection and maintenance activities. Understand waste. Life cycle costs Concept Design and development Key Elements - Reliability Maintainability Waste Elimination A design and manufacture must focus on these key elements. Ensure both customers and suppliers have a key input, particularly at concept stage but as much as practical throughout the design & build process Us e the “6 Big Losses” to focus on waste reduction needs Now more detail on - Reliability and Maintainability Focus on reliability and maintainability. Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

LIFE CYCLE COSTS Concept - 3% Design & Develop - 12% Operational & Support - 50% 50% of the costs incurred for a piece of equipment take place once it is operational, I.e. spares, maintenance, etc. That doesn’t include the further costs incurred through poor availability or inefficient processing. Equipment Build - 35% Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

CONCEPT Product. Customers and Suppliers. Define reliability and maintainability expectations. Production goals - Hours of work & demand (TAKT) Performance - Output - Life Waste elimination. Flexibility. Implementation plan. Key stage for involving all interested parties - must get the views based on current and proposed working conditions Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

DESIGN & DEVELOPMENT Man and machine - ergonomics, ease of access, health & safety. Formalise concepts. Incorporate standards Components User interfaces Standard maintenance equipment User/maintainer manuals Spares Component reliability/predictability (supplier data) Spares lists / stocking requirements Design must include elements which minimise/eliminate all the forms of waste and reduce the impact of the “6 Big Losses” Turn the concepts into a design reality that can be achieved for reliability and maintainability Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

DESIGN & DEVELOPMENT Audit against reliability and maintainability. Autonomous Maintenance. Effective Maintenance. Failure Mode and Effects Analysis (FMEA). Keep doing a check and balance against all aspects of the design to ensure they meet the agreed criteria of reliability and maintainability. From a maintainability perspective can design elements be included that allow condition monitoring and regular checks be done without major upheaval to machines, i.e. clear guarding, easily visible gauges, accessible lube points Have standards been met or are standards being set? FMEA to understand the types, reasons and likelyhood of failure of given component parts (Criticality Assessment and life-cycle predictions) Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

INFORMATION Planned Maintenance Effective Equipment Design Preventative Maintenance Predictive Maintenance Breakdown Maintenance What have been the key learning points? TRAINING AUTONOMOUS MAINTENANCE Slide Verbal Flip Chart Training Matl. Photo Prepared Flip chart Extra Info Available

Module: TPM Slide Verbal Photo Explain the key objectives:-

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Module: TPM Slide Verbal Photo Explain the key objectives:-

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