Planned Maintenance

Presented By
Akbar sha S8 Production

Department of Production Engineering Govt: Engineering college Thrissur

JISHU HOZEN

KOBETSU KAIZEN

PLANNED MAINTENANCE

SHEE PILLAR

TPM

10 PILLARS OF TPM

5S
Department of Production Engineering Govt: Engineering college Thrissur

QUALITY MAINTENANCE

EDUCATION & TRAINING

INITIAL FLOW CONTROL

OFFICE TPM

COMMON PROBLEMS & THEIR CAUSES

Static Equipments
1. Changes in equipment interiors (deformation due to corrosion, vibration , loose or fallen -off parts, etc. contamination , blocks , erosion, internal leaks , degradation of materials) Changes in equipment exteriors (leaks, corrosion , degradation of materials) Changes in measuring and control equipment (broken wires , shortcircuits, contamination , blockage , degradation of materials , programming errors, spurious signals)

Problems & Losses

1. Equipment failures or process problems causing shutdown Quality abnormalities Unit-consumption abnormalities Capacity reductions Safety and environmental problems
2.

2. 3. 4. 5.

Equipment Disorders & Hidden defects

3.

Rotating Machines
1. Changes in machine interiors and exteriors. (deformation due to corrosion, vibration, loose or fallen-off parts, etc.,contamination, blocks, leaks, erosion,) Department of Production Engineering Govt: Engineering college Thrissur

TWIN ACTIVITIES OF SPECIALISED MAINTENANCE

Specialised Maintenance activities

Improving Maintenance technology & Skills

1.Specialized maintenance skills 2.Equipment repair skills 3.Inspection and measurement skills 4.Equipment diagnostic techniques and Skills 5.New maintenance technology

Improving Equipments
1.Autonomous maintenance support 2.Planned maintenance (6 steps) 3.Corrective maintenance 4.Maintenance prevention 5.Predictive maintenance

Department of Production Engineering Govt: Engineering college Thrissur

Maintenance Regimes
Approach to Maintenance

Planned

Un Planned

PM

BM

CM

TBM

CBM
PM TBM CBM BM CM : Preventive Maintenance : Time-Based Maintenance : Condition-Based Maintenance : Breakdown Maintenance : Corrective Maintenance

Daily Checks

Periodic Checks

Periodic Inspection

Rotating M/C

Static Equipments

Department of Production Engineering Govt: Engineering college Thrissur

Time-based Maintenance
The goals of planned maintenance are to eliminate equipment failures and process problems and minimize losses. The first step toward achieving those goals, is time-based maintenance, Deciding what maintenance to perform on which equipment will depend on a company's policies, long- and mid-range plans, annual plans, and so on. To maintain equipment and processes in their ideal state.

Planning & Scheduling

Time based Preventive Maintenance activities

Checking and cleaning

Inspecting Parts replacement and servicing Repair Improvement
Lead to

Require

Maintenance technology and Maintenance skills

Action
Maintenance reliability Design reliability Reliability of function / performance evaluation

Department of Production Engineering Govt: Engineering college Thrissur

Condition-based Maintenance
The second principal activity of planned maintenance, condition-based maintenance, has two main thrusts: 1) Condition monitoring : This must occur while equipment i s running to gauge its functions and performance accurately. 2) On-stream inspection (OSI): This helps increase the precision of shutdown maintenance planning. In process plants, many maintenance tasks are performed during annual shutdown maintenance . If inspections during shutdown maintenance reveal defects that must be corrected, maintenance personnel must modify the shutdown maintenance plan. This can cause a delay in restarting the plant among other problems. Time-based and condition-based maintenance control the condition of the assemblies, subassemblies, and components that comprise a piece of equipment. It is critical to accurately identify and control all those components whose failure might lead to equipment breakdown or lost performance, cause quality defects Compromise safety or harm the environment.

Breakdown Maintenance in Planned Maintenance

The third main activity of planned maintenance, breakdown maintenance, consists of replacing parts or performing other repair work after equipment breaks down. To facilitate prompt repairs and prevention, make it easy for operators to detect abnormalities when they perform their daily checks or routinely monitor the equipment.
Department of Production Engineering Govt: Engineering college Thrissur

Planned Maintenance & M/C Lifecycle

Early equipment Management Equipment Management Planned Maintenance

Management during useful life

Scrap

Department of Production Engineering Govt: Engineering college Thrissur

Types of Maintenance System

Maintenance System

Centralised
maintenance technicians are assigned permanently to a maintenance centre managed by the maintenance department. The technicians o out to the shop floor or production site as required. This system is common in medium-sized plants with few maintenance personnel.

Decentralised
In a decentralised system maintenance technicians are assigned permanently to different work places. This system is common in large plants. Even in large plants, however, only mechanics are usually decentralized; electrical and instrumentation maintenance personnel typically remain centralized.

Mixed
In a mixed system, some maintenance personnel are assigned permanently to different workplaces, while the rest are based in a maintenance centre. Again, plants usually adopt the mixed system for mechanical maintenance and the centralized system for electrical and instrumentation maintenance.

IMPROVING MAINTENANCE EFFECTIVENESS

Improvement indicator:
Results (cumulative annual cost savings) Maintenance costs - annual depreciation of improvement investment
Department of Production Engineering Govt: Engineering college Thrissur

Planned Maintenance Activities

Activities to enhance Aviability
Guidance and support to Jishu Hozen
Activities to efficiently conduct the Maintenance
Maintenance work planning and Mangt

Corrective Maintenance activities

MP Activities

Predictive Maintenance

Establish Planned Maintenance System

Input Reductions
Department of Production Engineering Govt: Engineering college Thrissur

Maintenance cost mangt

7 step activities of PM

Enhancing Maintenance technology Skills

Management information Mangt

Spare part & Lubrication mangt

Zero Break Downs

7 Steps of Planned maintenance

Step -1 Support to Jishu Hozen Step 2 Evaluate equipment and understand situation Step -3 Reverse deterioration and correct weakness Step -4 Build an information management system Step -5 Build a periodic maintenance system Step -6 Build a predictive maintenance system Step -7 Evaluate the planned maintenance system
Department of Production Engineering Govt: Engineering college Thrissur

Four Phases to Zero defects

Department of Production Engineering Ispat industries Ltd. Govt: Engineering college Thrissur

Activities of 7 Steps in PM

Department of Production Engineering Govt: Engineering college Thrissur

Step 2 :Evaluate Equipment and Understand Current Conditions

To decide which equipment receives planned maintenance, prepare equipment logs and prioritize the equipment in accordance with Pre-established criteria.

Equipment Logs( Click Here)

Equipment logs are raw data for evaluating equipment. They must give design data and show the equipment's operating and maintenance history.

Evaluate and Prioritize the Equipment ( Click Here)

Evaluate each piece of equipment in terms of its effect on safety, quality, operability, maintainability Rank equipment (as A, B, or C) and perform planned maintenance on all units ranked A or B, as well as those M/c for which zero failure is a legal requirement.

Rank Failures
Rank failures as major, intermediate, or minor depending on their effect on equipment.

Understand the Failure Situation and Set Maintenance Goals

( Click Here)

To grasp the current situation, obtain data on failure numbers, frequencies, and severities, and on MTBFs (mean times between failures), MTTRs (mean times to repair), maintenance costs, and so on. Then set goals for reducing these through planned maintenance. Department of Production Engineering Govt: Engineering college Thrissur

Step 3 : Restore Deterioration and Correct Weakness

Until a plant establishes autonomous maintenance, equipment exposed to accelerated deterioration for many years can fail unexpectedly at irregular intervals.

Help operators to restore Deterioration

To understand and overcome the effects of deterioration in their equipment To abolish environments that promote accelerated deterioration: To establish basic equipment conditions:

Correct Weaknesses and Lengthen Equipment Life

Equipment may also suffer from inherent weaknesses generated during design, fabrication, and installation. Weaknesses may also become apparent when equipment is operated outside its design conditions

Prevent Recurrence of Failure

Use failure analysis to deal with the type of major and intermediate failures that halt production lines. Also investigate the possibility of similar failures that occur in other equipment and take steps to prevent them.

Reduce Process Failures

Corrosion, cracking, blocks, leaks, and accumulation of foreign matter in static equipment; vibration and blocking of pipes; perforation of heat exchanger tubes; and so on Changing properties of raw materials and subsidiary materials, disrupted services, misoperations, catalyst deterioration, and other process disorders. To minimize process failure losses, restore process conditions to normal as soon as possible after spotting signs of impending failure.

Department of Production Engineering Govt: Engineering college Thrissur

Step 4 : Build an Information Management System

In process industries, an enormous variety of equipment needs maintenance, and different processes require different maintenance regimes. Managing this colossal amount of information manually is impossible. The company must set up a computerized data-processing system.

Building a Failure Data Management System

A failure data management system should include certain information, which shift operators must enter in the database. Such information includes date and time ; failure rank (major, intermediate, minor); equipment model; failed component (shaft, coupling, bearing, etc .); nature of failure (vibration, abnormal noise, overheating, corrosion, wear, etc.); cause; action taken; effect on production ; and time and number of personnel required for repair. This data- should be analyzed and made available at regular intervals in the form of periodic failure summaries and equipment failure lists .

Computerizing Maintenance Budget Management

A computerized management system for the maintenance budget compiles, apportions, and totals maintenance budgets. It must generate Budget summaries for different types of maintenance work , Work and materials usage schedules, Job priority lists, Equipment life forecasts, and Charts that compare predicted downtime losses with maintenance costs and help measure maintenance effectiveness. Department of Production Engineering Govt: Engineering college Thrissur

Step 4 : Build an Information Management System

Building a System for Controlling Spare Parts and Materials
To analyze reasons for holding long-term stocks and to cut down on the labour required for calculating total usage and keeping track of issues and receipts, the following information is necessary: Lists of long-term stocks Materials usage tables Receipts/issues comparison tables
Building a System for Controlling Technical Information and Drawings A technology management system should control all information that relates to maintenance , including design standards, technical reports, important literature, checking standards, mechanical design calculation programs, equipment diagnosis criteria, and structural analysis data.
Department of Production Engineering Govt: Engineering college Thrissur

Step 5 : Build a Periodic Maintenance System

In periodic (or time-based) maintenance, standby units, spare parts, inspection equipment, lubricants, and technical information such as drawings may be required to carry out the scheduled work. Maintenance work proceeds smoothly only if these resources are properly prepared in advance.

Periodic Maintenance Procedure( Click Here)

Selecting Equipment and Components for Periodic Maintenance

Department of Production Engineering Govt: Engineering college Thrissur

Selecting Equipment and Components for Periodic Maintenance

Equipment that, by law, requires periodic inspection Equipment with maintenance intervals determined by experience Equipment that requires regular checking because of its importance to the process Equipment with an established replacement interval based on the serviceable life of its components Equipment, such as heat exchangers, whose performance begins to deteriorate after a known period as a result of scale build-up and so on Important equipment for which it is difficult or impossible to detect or correct abnormalities during" 0peration

Department of Production Engineering Govt: Engineering college Thrissur

Daa Pottaaa Following slides to be added

Slide 25 Shut down and breakdown maintenance ( 2 or 3 lines nothing in detail) Slide 26 Building Predictive Maintenance system (Contains what is predictive maintance) Slide 27 Predictive Maintenance Flow diagram Slide 28 Vibration analysis, Ultrasonic Testing ,Oil lubricant analysis Slide 28 Evaluation Of PM

Department of Production Engineering Govt: Engineering college Thrissur

MTBF Mean Time Between Failures

MTBF = Total time-Total Down Time Number of breakdowns

Example : (SMS Delays Dec10) Delay duration = 886 Minutes B/d occurrences = 27 Total time (month) = 31*24*60=44540 minutes MTBF (in hours) =(44540-886)/(27*60) = 26.94 Hours MTBF is an indicator of reliability of the components/machines/ plant. Higher the value of MTBF, higher is the reliability of the Components/Machines/ plant.

Department of Production Engineering Govt: Engineering college Thrissur

MTTR Mean Time To Repair

MTTR = Total Down Time Due To Break Downs Total Number Of Breakdowns Example : (SMS Delays Dec10) Delay duration = 886 Minutes B/d occurrences = 27 MTTR (in minutes) =886/27 = 27.8 minutes MTTR is an indicator of maintainability . Lower the value of MTTR better is the maintainability of the equipments.

Department of Production Engineering Govt: Engineering college Thrissur

Department of Production Engineering Govt: Engineering college Thrissur