MAINTENANCE &TPM

Gopalakrishnan - Role Of
Maintenance

WHY MAINTENANCE?
If left unattended, everything will
deteriorate so, maintain
Make the equipments available for
production at all times
Prevent the equipment from Forced
deterioration
Maintain the condition of the equipment
Improve the performance & reliability of
the equipment
Gopalakrishnan - Role Of
Maintenance

Equipment Condition

What is FORCED DETERIORATION?

Natural Deterioration

Forced Deterioration

Time
Gopalakrishnan - Role Of
Maintenance

ROLE OF MAINTENANCE
AIM:
Zero Breakdowns
Improve the Quality of maintenance
activities
APPROACH:
Trap Defects
Progressively eliminate the root causes
Gopalakrishnan - Role Of
Maintenance

PROGRESS MEASURES
MTBF: Mean time Between Failures
MTTR: Mean Time to Repair / Rectify
Problems Understood
Counter measures applied
---------------------------------- x --------------------------------- x
Problems Known
Problems understood

Gopalakrishnan - Role Of
Maintenance

Successful countermeasures
--------------------------------------Counter measures applied

Periodic
Maintenance

Periodic Tests

Service

OP

Preventive
Maintenance

Trend Tests

Rectify

ENG

Breakdown
Maintenance

Rapid
Abnormalities

Repair

RELIABILITY

Normal operations

Setup &
Adjustments

Daily Maintenance

Cleaning as
Inspection

Maintenance
Activities

TARGET

MAINTAINABILITY

Improvement
Activities

OEE
TARGET 85%

Classification & Allocation of Maintenance Activities

METHOD
ACTIVITIES
Prevent / Measure / Restore

Gopalakrishnan - Role Of
Maintenance

ALLOCATION
Operators / Engineers

OP

OP

Strengthen
Reduce Load
Increase Precision

Condition Monitor
Test Procedures
Standardization

ENG

ENG

ENG

TOTAL PRODUCTIVE MAINTENANCE

PRODUCTION
QUALITY
COST
DEVELOPMENT
SAFETY
MORALE

Gopalakrishnan - Role Of
Maintenance

POLICY
Our TPM Policy is to achieve

Higher Overall Equipment Efficiency

With reduced losses and

High reliability of our process.

We commit to achieve this policy through

Zero Breakdowns ,

Zero Defects and

Zero Accidents.

To achieve this, continuous skill up gradation of employees

will be done.

Gopalakrishnan - Role Of
Maintenance

PRINCIPLES
Increase OEE
Improve existing Planned Maintenance systems
Routine Asset Care as a part of the job
Increase Skills

TRAIN OTHERS

Maintenance Prevention

USE

Gopalakrishnan - Role Of
Maintenance

KNOW

UNDERSTAND

PILLARS

FOCUSSED (SELF) IMPROVEMENT

AUTONOMOUS MAINTENANCE
PLANNED MAINTENANCE
QUALITY MAINTENANCE
EDUCATION & TRAINING
DEVELOPMENT MANAGEMENT
SAFETY HEALTH ENVIRONMENT
OFFICE TPM
Gopalakrishnan - Role Of
Maintenance

GOAL OF TPM
GOAL:
Increase OEE
Develop optimal relationship between equipment and
people
METHOD:
Eliminate Six Losses
THROUGH:
Measurement Cycle
Condition Cycle
Prevention Cycle
Gopalakrishnan - Role Of
Maintenance

OVERALL EQUIPMENT EFFECTIVENESS

OEE is a product of
Availability Rate x Speed Rate x Quality Rate
AR = No. of hours m/c run / No. of hours available
SR = No. of pcs produced / Standard production

QR = No. of pcs Accepted / No. of pcs produced

Gopalakrishnan - Role Of
Maintenance

SIX BIG LOSSES

1.
2.
3.
4.
5.
6.

BREAKDOWN LOSSES
SET-UP & ADJUSTMENT LOSSES
IDLING & MINOR STOP LOSSES
REDUCED SPEED OPERATION
SCRAP & RE-WORK LOSSES
START-UP LOSSES

7th loss is Blade-loss

Gopalakrishnan - Role Of
Maintenance

MEASUREMENT CYCLE
COLLECT HISTORY FILE
IDENTIFY THE ORIGINAL SPECIFICATIONS
OF THE EQUIPMENT SUPPLIED BY THE
MANUFACTURER
COLLECT PERFORMANCE DATA OF THE
EQUIPMENT vis--vis SPECIFICATIONS

DEFINE REVIEW PERIOD BASED ON THE

DATA COLLECTED
Gopalakrishnan - Role Of
Maintenance

CONDITION CYCLE
CRITICALITY ASSESMENT OF THE
EQUIPMENT
CONDITION APPRAISAL FOR THE
EQUIPMENT
PLAN REFURBISHING

PREPARE FUTURE CHECK-LIST BASED ON

THE OBSERVATIONS
Gopalakrishnan - Role Of
Maintenance

PROBLEM PREVENTION
STANDARDIZATION OF ACTIVITIES
P-M ANALYSIS (PHENOMENON
MECHANISM ANALYSIS)
SIMPLY, DO

AUTONOMOUS MAINTENANCE
Gopalakrishnan - Role Of
Maintenance

TPM
Gives us special lens to see things
Drives us to do more focus on process
Enables us to have control over the
equipments downtime
Allows us to challenge Status Quo
Forces us to Improve
Helps us to Work Smarter
Gopalakrishnan - Role Of
Maintenance