maintenance english
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H A S H M A N A G E M E N T S E R V I C E S L L P
C H E N N A I
P H : 9 1 7 6 6 1 3 9 6 5
The Essentials - Maintenance
Overview
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‘The Essentials’ series from Business Sense is an initiative to empower the students(freshers) and
professionals in performing more efficiently and effectively in the organization
This document is a part of the “Certified Manufacturing Professional” course offered by Business Sense
This course is aimed at bridging the gap between the institutions and the industry by providing the
fundamentals of manufacturing management which are not offered by any of our
institutions/curriculum
This course would immensely benefit students and professionals who are joining manufacturing
organizations
For more details, please visit www.businessense.in
At Business Sense, we help clients through consulting engagements focusing on improving their
Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools.
We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply
Chain Re-engineering.
You can subscribe to our bi-weekly newsletter here.
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Contents
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Section 1 – Introduction and Basic Processes
Section 2 – Autonomous Maintenance
Section 3 – Pictorial Representations
Introduction to Maintenance Function
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Maintenance function ensures that all the machines and equipments related to
the production and other key functions in the organization are maintained and
function properly
Maintenance Function plans for the spares and consumables for the
maintenance
They co-ordinate with outside agencies / other functions in case of layout
change / wiring / machine movement, etc
Maintenance should ensure that there should not be any breakdowns of any
machines
Responsibilities of an Engineer in the Maintenance Function
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To bring the machine to the working condition, in case of a break-down
Improving the performance of the machines to the specified levels of
performance
To Move towards Zero Failures , Zero Defects & Zero Accidents
Analyzing and stocking the Vital, Essential and Desired spares through VED
Analysis
Maintaining a MIS report of Break-down register and Preventive Maintenance
schedule
Coordinating and supporting during layout changes and new machine
installations
Types of Maintenance
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There are 2 basic types of maintenance
Break-down Maintenance – Done after the Machine breaks down
Preventive Maintenance – before the Machine breaks down - done by the Maintenance team at
regular intervals to keep the machine in working condition
Autonomous Maintenance (AM) is a part of Preventive Maintenance (PM)
AM is done by the operator themselves on a daily basis
Over a period of time, Break-downs of machines should become zero!
Break-down Maintenance
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Once a particular machine breaks down, the operator informs the
production supervisor to raise a complaint to the Maintenance team
Maintenance team rushes to the machine and fix the issue
Most companies have a Service Level Agreement with the Maintenance team
to attend the machines ( e.g. maintenance team personnel should reach the
machine with in 30 min )
Preventive Maintenance
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This is a schedule based maintenance program which would be done by
the maintenance team
Daily / weekly / fortnightly / monthly / quarterly plan for all machines
A preventive Maintenance calendar should be created covering all
major machines in the company and person responsible for the same
Autonomous Maintenance (AM)
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Would be done by the operator themselves
Cleaning / Lubrication / Re-tightening / Inspection are covered under
Autonomous Maintenance
Minor spare change can also be covered under AM
Steps for Implementing AM
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1. Preparation
2. Cleaning and Inspection
3. Eliminate Problem Sources and abnormalities
4. Cleaning, Lubrication, Re-tightening, Inspection – Checklists and Audits
5. Visual Management
Please note that this list covers only the basics. This is not the exhaustive list of steps as prescribed by the TPM model
Step 1- Preparation
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Identify the Machine parts and the purpose /activity of the part in the
machine
Know the function of the machine
Know the safety aspect of the machine
Operator Training to handle the machine
Knowing the machine & its parts is the primary step
Step 2- Cleaning and Inspection
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Initial Cleaning of the Machine
Identification of
Abnormality
Hard to Access area
Source of Contamination & Localization
Unsafe Conditions
Step 2- Initial Cleaning of the Machine
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Before cleaning, all WIP materials in the machine to be properly covered.
Cleaning Agent should be applied as mentioned in the manual of the machine
only
Cleaning tools:
Cotton Waste
Tool Box / Trolley
Wire Brushes
Ladder , Screw Driver
Emery Sheet - Medium
Cleaning Agent – Kerosene , Soap oil
Step 2- Identification of Abnormality
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Dust
Dirt
Leak
Rust
Loose
Damage
Deformed
Bolts and nuts/ joints
Lubrication
Transmission
Hydraulics
Pneumatics – gas system
Electrical
Safety
Non standard
Vibration
Noise
Misalignment
Shaking
Worn out
Missing
Abnormalities Where to find them?
Step 3 – Elimination of abnormalities
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Missing Nut Nut fixed
Step 3 – Elimination of abnormalities
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Different Nuts Same type nuts Remaining steps with pictures and Report templates are explained in the “Certified Manufacturing Professional” course. To access login to www.businessense.in
End of Free Content
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Please visit our website www.businessense.in to access the full course – “Certified Manufacturing
Professional”
Our website also contains list of ready-to-use templates and report formats containing Charts and
pivot tables.
Templates and report formats are available for Purchase, Stores, Production, Quality, Maintenance and
HR functions
These templates come in excel /word and can be downloaded and used right away
At Business Sense, we help clients through consulting engagements focusing on improving
their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and
other tools.
We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and
Supply Chain Re-engineering.
You can subscribe to our bi-weekly newsletter here.
Follow us: