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8/6/2019 Module III bu pom notes
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Asst Prof Arvind Gajakosh
BE, MBA, NET
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Machines, equipment etc are going to havedeterioration with age. They will have the effectof wear and tear, temp, vibrations and looseness.
In addition to these there will be accumulation ofdust, rusting of parts over time.
The process of deterioration is reflected in
Inability to the m/c to take up specified load.
Inability to the m/c to produce quality goods.
Reduction in the useful life of the variouscomponents of the m/c parts.
Increased hazards to the safety of employeesworking on or near the m/c.
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Maintenance may be understood as a set of
activities which help keep plant, machinery &
other facilities in good condition.
Loses resulting from breakdowns Cost of repairs
Reduced life of the equipment
Effect on other machines
Added set up costs Loss of materials
Idle wages to workers
Increase in work in progress investment
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Ensuring maximum plant availability by preventing
unexpected breakdowns & by reducing shutdown
periods.
Maintenance of equipment at its ratedproductivity and original accuracy.
Minimization of wear & tear to increase the
longevity of the equipment.
Elimination of unsafe conditions that causeaccidents there by ensuring safety of workmen.
Increase in productivity of machines through
improvements and modifications made during
scheduled overhauls(take apart).
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Breakdown or corrective maintenance
Preventive maintenance
Predictive maintenance
Routine maintenacne
Breakdown or corrective maintenance
Maintenance work performed to restore an
equipment back to its acceptable performance.
Since no attempt is made to prevent the
occurrence of the fault b/d maintenance is also
called as operate to fault maintenance.
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Preventive maintenance
Repair of machines at planned intervals so that
sudden breakdowns could be prevented and costly
down time avoided. This work can be done during off shift hours or
holidays.
Maintenance work performed at predetermined
intervals, or to other pre set criteria with an aimto reduce the possibility of the equipment not
meeting an acceptable performance.
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Predictive maintenance
One of the newer type of maintenance that may
be anticipated to gain increasing attention is
called predictive maintenance. Conditions can be measured periodically or on a
continuous basis.
This will allow an extension to the service life
without fear of failure. Routine maintenance
This includes activities such as periodic inspection,
cleaning, lubrication & repair of production
equipments.
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TPM is a mgmt system for optimizing the
productivity of manufacturing equipment through
systematic equipment maintenance involving
employees at all levels. The goal of TPM is to markedly increase production
while at the same time, increasing employees
morale & job satisfaction.
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Aim at the creation of collective culture relating to
the attainment of maximum efficiency throughout
the production process.
Use the sys so as to prevent losses & to reach theZero accident, Zero defect & Zero
breakdowns, in the manufacturing process.
Involve the entire work force from bottom to top.
Obtain zero losses by integrating the activities ofteams with the production system.
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TPM eliminates 6 big losses which are as listed below Breakdowns which can result in long, expensive
repairs.
Set ups & changeovers which can take much longer
time than needed. Idling & minor stoppages which are hard to quantify
and add up to big losses.
Reduced equipment speed which results in gradual
deterioration of equipment cycle times.
Defects & rework which results in quality losses &
unhappy customers.
Start-up losses which can take much time to get
steady state after a change.
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Increased equipment productivity
Reduced equipment downtime
Increased plant capacity
Lower maintenance & production cost
Approaching zero equipment caused defects
Improved return on investment
Ensuring pollution control measures
Better understanding of the performance of
equipments.
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MTBF = Total Running Time
Number of Failures
Speed (%) efficiency = Actual cycle time * 100
Design cycle time
Quality (%) efficiency = Good parts produced * 100
Total parts produced
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OEE% = Availability * Performance * Quality
Availability = Operating time
Available time
[Operating time = Available time - idle time]
Performance = Ideal cycle time * Piece produced
Operating time
Quality = Good pieces
Total pieces
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5 S
Jishu Hozen
Kaizen
Planned Maintenance
Quality Maintenance
Training
Office TPM
Safety, Health & Environment
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The different S are as follows:
Serie (sort)
Seiton (systematise organize)
Seiso (sweep clean)
Seikersu (standardize)
Shitsuke (self-discipline)
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Serie (sort):
This means sorting & organizing items as per the
frequency of usage. If the items are used once per
year they can be stored away from the work place. If the items are used once per month or once per
week, they can be stored together but off-line.
If the items are used daily, they should be stored at
the work place itself.
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Seiton (systematise organize)
The items should be stored in an organized way.
There should be place for each item & each place is
assigned with only one item. Name plates andcoloured tags may be used for easy identification.
Seiso (shine the work place): this means that the
work place should be cleaned such that it is free frmburs, grease, oil, waste,scrap, etc.
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Seiketsu(standardization): the employees should
decide the standards for keeping the work place,
machines, assails in neat and clean condition.
The standard should be inspected randomly.
Shitsuke(self-defence): this means that the
employees should treat 5 S as their way of life
and develop self discipline by way wearing
badges, following work procedures, punctualityand dedicating themselves to the organization,
etc.
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kaizen means change for the better in Japanese.
The foundation of Kaizen model consists of five
elements which are : Team work, Personal
discipline, Improved morale, Quality circles &suggestions for improvement.
Kaizen focuses on zero losses, cost reduction in all
resources, improvement of overall plant
effectiveness.
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Planned maintenance aims to have trouble free
machines & equipments to produce defect free
products to fully satisfy customers requirements.
This planned maintenance is classified into
breakdown, preventive, & predictive maintenance.
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Quality maintenance aims to maintain the
equipments in good operating condition such that
highest quality products are delivered to customers
through defect free manufacturing.
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Training is an important pillar in TPM which
emphasizes educating operators to upgrade their
skill. It is not sufficient to know only know-how
but they should also learn know-why.
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This a mainly aims to improve the productivity &
efficiency in the administrative functions by
indentifying & eliminating losses in them.
This is achieved by analyzed processes &procedures for enhanced office automation.
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These things aim to have zero accident, zero
accident, zero health damage and zero fires.
One can achieve these things by creating a safe
work place and a surrounding area that is notdamaged by the processes and procedures.
The awareness among employees can be created
through competitions like, safety slogans, quiz,
drama, posters, etc. which are organized at regular
intervals.
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