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Fault deduction
Fault isolation
Fault elimination
Adjust/align/caliberate
Repair
Remove and replace
Verification that the fault has been
eliminated
Preventive maintenance
It is undertaken before the need arises.
It consists of
Proper design and installment of equipment
Periodic inspection of plant and equipment
Repetitive servicing of equipment
Usually preferred for machines which are costly
Benefits are:
Greater safety to workers,
Decreased production downtime
Fewer large scale and repetitive repairs
Less standby equipment required
Planned and preventive
maintenance
Maintenance request
Maintenance schedule
Work/job specification
Planned maintenance programmes
Annual/weekly plan
inspection report
History records
Planned lubrication
Work priority
Safety
Predictive maintenance
Sensitive instruments (like vibration
analysers, pressure temperature
gauges ) are used to predict the
trouble.
Conditions can be measured
periodically or on continuous basis
Routine maintenance
Includes activities such as periodic
inspection, cleaning, lubrication and repair
of production equipments after their service
life.
It can be classified into two
Running maintenance: In which maintenance
work is carried out while the equipment is in the
operating condition.
Shut down maintenance: In which
maintenance work is carried out when the
machine or equipment is out of service.
Design out maintenance
Aims to eliminate the cause of
maintenance
Choice between
Cost of redesign + reduced maintenance
cost v/s Recurring cost of best
maintenance procedure
Steps in design-out
maintenance
Identify the defects causing High maintenance
cost
Look into the possible causes of the defect
Identify the possible solution to eliminate the
cause
Suggest the necessary modification
eliminating or reducing the effect of the defect
Compare financial benefits against
investment required
Assess the degree of risk with new modification
Total Productive
maintenance
Developed in Japan in 1971
The word TOTAL has three important
features in TPM
Total effectiveness: Economic efficiency
or profitability
Total preventive maintenance to improve
maintainability
Total participation: Autonomous
maintenance by operations and small group
activities in every departments at all level.
It tries to eliminate six big
losses
1. Break downs due to equipment
failure
2. Set-up and adjustment
3. Idling and minor stoppage due to
abnormal operation of machine
components
4. Reduced speed of operation
5. Defects in process and rework
6. Reduced yield between machine
start-up and stable production
Condition monitoring
technologies
Vibration monitoring
Thermography
Oil debris monitoring
Performance monitoring
Flow, pressure, energy consumption