PLANNED MAINTENANCE

GOALS To focus on preventive actions to eliminate equipment failure/ breakdowns in order to ensure availability and reliability of equipments and to minimize cost of maintenance.

APPROACH
1. Maintenance Activities -To prevent failures. -To enhance availability/ reliability. 2. Improvement Activities. -To extend life span of parts. -To shorten maintenance time. -To avoid maintenance.

METHODOLOGY
Step 1- Support and guidance of Autonomous maintenance. Step 2- Evaluation of equipment failure/ breakdowns. Step 3- Restore detoriation and correct weakness. Step 4- Build an information management system. Step 5- Build a periodic maint. System. Step 6- Build a predictictive maint. System. Step 7- Evaluate planned maint. System.

SUPPORT AND GUIDANCE OF AUTONOMOUS MAINTENANCE

Educate operators regarding equipment mechanism and how to find abnormalities by cleaning and inspection. Countermeasures against sources, hard to access the area. Assistance in preparing standards. Assistance in continuous improvement of Autonomous maintenance.

EVALUATION OF EQUIPMENT FAILURES/ BREAKDOWNS

Collect data of all failures/ breakdowns. Prepare equipment control ledger. Decide the equipments to be taken for preventive maintenance. Understand the nature of losses and the equipment importance. Set targets for equipment failures/ breakdowns.

RESTORE DETORIATION
Restoration detoriation by inspection using optimal condition check sheets. Small group activities of operation division should be technically supported. Defects and weak points of design to be found out. Using Why, Why analysis countermeasures are to be implemented. Improvements are to be made to strengthen weak points of design. Create M.P. Sheet. Maintenance-skill in the above to be improved.

ROLE OF MAINTENANCE
Abolish the environment causing forced detoriations. To find out, whether the breakdowns are natural or forced. If the breakdowns are natural, find out the weak point of the design and improve by Kaizen. Follow the TBM and CBM for vital and essential parts of the equipment.

TBM
Time Based Maintenance activities are selected on the basis of Equipment suppliers recommendation and past performance of the equipment Periodic inspection, cleaning, lubrication, oil replacement, parts replacement and services are carried out at predetermined intervals to restore equipment detoriation.

CBM
Standard vibration limit. Standard bearings temperature limit. Frequency of measuring points. Value within limit. Fault predicted.

INFORMATION MANAGEMENT SYSTEM

Feed the equipment history i.e. B/D maintenance report, failure analysis report, preventive report etc. Using equipment data and history arrive at monthly, yearly preventive maintenance plan. Spares inventory control.

PERIODIC MAINTENANCE SYSTEM

Prepare time based work system flow to carry out the activities. The efficiency of TBM could be felt in reliability and equipment cost. Kaizen related to life span improvement of parts, easy maintibility are to be arrived. Revisit optimal condition check sheet and correct wherever necessary.

PRIDICTIVE MAINTENANCE SYSTEM

EVALUATION OF PLANNED MAINTENANCE SYSTEM

Anand dubey