Plant-Wide Maintenance Methodologies Flashcards
Four absolutely necessary T’s
For employees to provide error-free work:
1) Training
2) Tools
3) Time
4) Teams
(TPM)
Total Productive Maintenance
*Strives to maximize output by maintaining ideal operating conditions and running equipment effectively.
*An operational strategy focusing on maximizing overall equipment effectiveness (OEE); requires full organizational participation to be successful.
(OEE)
Overall Equipment Effectiveness
OEE = Availability *
Performance Rate *
Quality Rate
TPM’s Six Big Losses
A) Availability
1) Breakdowns
2) Set-up and adjustment (not a maintenance issue)
B) Performance rate
3) Idling and minor stoppages
4) Reduced speed
C) Quality rate
5) Quality scrap and rework
6) Equipment start-up (resulting scrap)
1st Loss: Breakdowns
1) Maintain operating conditions
a) Housekeeping to notice details
b) Lubrication
c) Simple adjustments
d) Monitor machine health with predictive maintenance (PdM) tools
2) Comply with PM schedules
a) Invest time to prevent breakdowns
b)Avoid start-up mishaps
c)Improve reliability (ERIC)
3)Provide training
a) How should PM be performed?
b) How should operators interact with the equipment to identify deterioration signals and avoid mishaps?
c) Plan the maintenance intervention (spare parts, tooling, people, sequence of tasks)
3rd Loss: Idling and minor stoppages
Minor stoppages:
a) Caused by a failure or error in the automatic handling, processing, or assembly of parts or work pieces.
b) Caused by the occurrence of a quality-related abnormality.
c) Are easy to fix, but their frequent occurrence impacts downtime.
d) Some means for counting stoppages is required; PLC logic can be added for this purpose.
e)Progress can be measured with mean time between failure (MTBF) monitoring.
2nd Loss: Set-up and adjustment
SMED / QCO
methodology
4th Loss: Reduced Speed
1) Typically related to equipment deterioration
-Excessive noise and vibration due to part wear.
2) Investment in machine refurbishing typically required.
-Part replacement or system redesign.
3) Equipment velocity should respond to line balancing requirements. Run at lower speed if it makes sense; should extend life!
5th Loss: Quality Defects
1) Typically related to equipment deterioration
-Lack of PM.
-Lack of process capability; unwanted process variability.
2) Need for understanding of:
-Product specs;
-Material specs to benefit product;
-Critical equipment capability to comply with product specs.
3)Process variation versus specs
6th Loss: Equipment Start-up
1) Scrap generated while equipment is adjusted.
2) Occurs:
-After PM;
-After product changeovers;
-After shutdown; during start-up.
3) Challenges:
-Capture/mark settings prior to PM and position machine in desired setting after PM is completed;
-Define machine settings by product and include as part of changeover;
-Identify “best” shutdown tactics and document to follow same steps every time!
(RCM)
Reliability Centered Maintenance
Company-wide program pursuing the preser-vation of equipment functions through the recog- nition of specific failure modes (FMEA) by equipment section, that can potentially produce unwanted performance (downtime, scrap, etc).
ERIC Elements
1)Preventive Maintenance (PM)
2)Quick ChangeOver (as applied to maintenance)
3)Autonomous Maintenance
4)Predictive Maintenance
5)Reliability Centered Maintenance
6)Computerized Maintenance 7)Management System (CMMS)
8)Component 9)Replacement/Redesign
10)Assembly Redesign
Preventive Maintenance (PM)
The actual intervention on the equipment, typically scheduled, that should prevent equipment malfunctions.
Quick ChangeOver (as applied to maintenance)
The planning and execution of PM; the challenge is to perform the PM in the shortest duration possible. Planning involves defining spare part, tooling and people needs depending on the sequence of tasks (serial vs parallel). Execution requires performing as planned.
Autonomous Maintenance
Simple short-duration maintenance tasks typically assigned to equipment operators, such as, house-keeping or cleaning, lubrication and adjustments.
