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Productive Maintenance

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

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Productive Maintenance

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  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: PreventDowntime • 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!

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