Plant Maintenance

Step 1: Evaluating equipment failures and assessing the current situation.Stem 2: Restoration and improvement of deteriorated equipmentStep 3 : Tentative standard Maintenance ProcedureStep 4: Total inspection of quality functionStep 5: Improvement of inspection and maintenance efficiencyStep 6: Execution of preventive maintenance

Step 7:Horizontal replication

7 steps of planned maintenance

Benefits of planned maintenance

• The quality of the part is maintained,• Increase in production up-time,• Reduced cost of operations,• Reduction in the number of machinery required,• Improving equipment capability and reliability – increasing

the mean-time-between-failures (MTBF),• Improving equipment maintainability by reducing sporadic maintenance time – reduction in the mean-time-to repair

(MTTR),• Establishing/improving predictive maintenance,• Reduced maintenance costs.

PM Support to JH

1.Prepare the line diagram

2.Prepare the cleaning Tools

3.Arrange the RED & WHITE Tag

4.Educate the 7 types of abnormality

5.Counter measure for red tags

6.Visuals for step No:1

• Collection of Equipment failure data• A Negative Map to be prepared• Equipment to be ranked

– equipment is ranked as A, B or C, based on the severity of the failure and its effect on safety, quality, production and maintenance. An “A” machine is most critical, causing safety risks or quality defects during a failure, while a “C” machine will cause no major issues in the event of a breakdown

• MTTR to be calculated• MTBF to be calculated • Goal setting

Step 1: Evaluating equipment failures and assessing the current situation.

Types of Maintenance

• breakdown maintenance,• periodic maintenance

– Time based Maintenance(TBM) or Inspection and repairs

• predictive maintenance – Condition based maintenence

• corrective maintenance

PM Step 2 Procedure