CATANDUANES STATE UNIVERSITY

COLLEGE OF INDUSTRIAL TECHNOLOGY

GRADUATE STUDIES

COURSE TITLE: PHYSICAL PLANT AND FACILITIES LAYOUT

TOPICS: PURPOSE OF MAINTENANCE
MAINTENANCE POLICIES
TYPE OF MAINTENANCE
FIVE-STEP KAIZEN MOVEMENT
5 S’s ASSESSMENT FORMS

PROFESSOR: ARC. JOSE G. ONG

REPORTER: MARY GRACE O. OLONAN

INTRODUCTION:

Maintenance is sometimes regarded merely as repairing equipment that has broken down, but
the principal purpose of maintenance is to keep equipment in working operation and to prevent failure.
In maintenance system,” down time “often brings the biggest expense. A failure during production time
halts production, delay shipments, and idle machines. A program of regular inspection and lubrication is
perhaps a key of preventing costly equipment failures. All machines, equipment and physical facilities
are subject to wear, deterioration, obsolescence, breakdown, and failure. If they are to be kept in good
working condition, they must be maintained.

I. PURPOSE OF MAINTENANCE

1. To safeguard equipment
2. To keep all the productive assets of the company in efficient working condition and to
minimize idle equipment time which interrupts or restricts a planned production
program.
3. To prolong the working life of plant and services
4. To help production and add to its efficiency by initiating satisfactory working conditions
and proper health and social amenities to the workers.
5. To install and maintain safety devices to prevent accidents caused by machinery, or
explosion.
6. To provide reliable advice to the management in their decision on the replacement of
the old plant.
7. To maintain statistics of plant costs and other expenses of maintenance of facilities.
8. To improve plant operation while it is set for production and to maintain efficient and
economic productivity.
 II. MAINTENANCE POLICIES

The following criteria may prove to be relevant in the formulation of such policies:

1. The performance and the nature of construction of the plant involved.

Where high performance requirements are exacting on a modestly designed equipment,
a very careful maintenance maybe extremely necessary.

2. The nature of the machine environment.

Where the plant has to operate under very adverse conditions of heat, dust, abrasion,
and corrosion, maintenance maybe more frequent.

3. The manner of plant grouping.

Where machines operate individually rather than as a group, maintenance would not be
very critical. Failure of one machine may not affect the operation of others.

4. Hazards and safety requirement

For hazardous equipment, a higher maintenance standard must be kept.

5. The character of maintenance operation.

The type of maintenance followed is determined by the amount of dislocation and work
stoppage.

6. The nature of anticipated plant failure.

The risks, frequency, and the kind of repair involved also determine the type of
maintenance to be adopted.

III. TYPES OF MAINTENANCE

a. Daily routine inspection and servicing- includes lubrication and checking gauges and
safety devices, belts and chains and others. These are usually done at convenient
moments of stoppage or while in the operation by the operator himself.

Advantages:
The advantages of the above method are the absence of clerical work, the dispensing of
a maintenance staff specially qualified for a job, unity of control, and economy of
production.

Dis advantages:
The methods suffer from the lack of control on maintenance costs and records
discontinuity in maintenance techniques due to change of operating personnel, risk of
 neglecting maintenance for emergency production, and the difficulty of organizing a
trained squad for a major emergency.

b. Scheduled maintenance – is programmed to provide for more extensive inspection and

for the overhauling of parts to prevent serious break downs and unwarranted
interruption in the workflow. This type of maintenance facilitates forward planning of
machine overhauls and effective utilization of maintenance worker.
The inspection of the plant is usually done during night shifts or at weekends.

c. Preventive Maintenance- this aims at eliminating repair jobs altogether and is

concerned with the upkeep, replacement, and modification of plants. This method
renders a more effective use of manpower and material and helps to attain a greater
efficiency in plant operation.
Advantages:
1. Satisfactory maintenance of plant standards at extremely low cost.
2. Flexibility of operation on account of accurate pre- knowledge of plant
conditions.
3. Lowest possible plant depreciation.
4. Accuracy of production forecast.
5. Better working conditions for maintenance labor.
6. Satisfactory maintenance of plant standards at extremely low cost.

d. Outside contract maintenance- some pieces of equipment are serviced by the supplier
companies themselves as part of the purchase contract of the equipment.

e. Breakdown Maintenance- In this case, maintenance, organized as a separate section, is

called into service when plant failure impedes, limits, or prevents the desired rate of
production. This system is suitable under the following conditions:

1. There is temporary urgency of production for a limited and difinable period.

2. Plant capacity exceeds the current market demand.
3. The process is obsolete and more modern equipment is under consideration.
4. Many standardized units are concerned, a short plant life is economically justified,
and replacement is easy.

The system is unsuitable under the following conditions:

1. Market demand exceeds plant capacity
2. Shortage of storage facilities necessitates continuity of production.
3. Large quantities of work – in – process materials cannot be recovered due to
breakdown.

Further dis advantages are heavy depreciation, increased cost of plant spaces,
inadequate utilization of machinery, in efficient use of both production and
maintenance labor, unreliable production forecast, poor working conditions for
maintenance personnel, and increased loss of material on production due to
breakdown.
 IV. KAIZEN
Kaizen is a Japanese word for the idea that explains the management’s role in the
continuous improvement of the processes and products by involving everyone in the
organization. Kaizen focuses simplification by breaking down the complex process into their
sub-processes and solving them. Kaizen is possible only when management is able to hear
the workers. It requires an effective communication in both the directions. Suggestion
system to improve the processes and rewarding those who gave suggestions are required
for enabling continuous improvement.

Example of Kaizen type improvement

To change the color of the walls from red to white to have better visibility. This
may not result in a great improvement.

Kaizen requires the use of the following :

1. The data about value adding and non-value adding activities.

2. The knowledge about various types of wastes( Muda)
a) Over production b) Delay c) Transportation d) processing
3. Principles of time and motion study and the use of group technology
4. Documentation of the operating procedures.
5. Following general housekeeping – The 5S concept.
6. Fewer inventories – Use of Just –in-time (JIT) techniques.
7. Mistake proofing by following Poka- Yoke principles.
8. Effective use of teams to solve problems and to improve the performance.

FIVE – STEP KAIZEN MOVEMENT

1. SEIRE ( STRAIGHTEN UP)

a) Work- in –process
b) Unused machinery
c) Junk materials
d) Papers and old documents
2. Seiton ( putting things in order) – Things must be kept in order so that they are ready for
use when required.
3. Seiso ( Clean up)- This step makes it mandatory to keep the workplace clean.
4. Seiketsu( Personal Cleanliness) – make it a habit to clean and tidy.
5. Shitsuke( Discipline) –adhere to the procedures in the workshop.

Reference: PRODUCTION MANAGEMENT FOR THE PHILIPPINE SETTING, ANDRES TQD(2001)

PRODUCTION MANAGEMENT, 3RD EDITION MARTINEZ ESDRAS