5.3 Horizontal Replication of Equipment Management and Quality Management to Other Lines

Only half the potential results will be achieved if Effective Maintenance is not pursued hand-in-hand with Autonomous Maintenance. The results achieved on the model line should be rolled out to other lines only after full consensus has been achieved with the operating department about who is to be responsible for which tasks. In practice, however, this has to be done while still attempting to cope with a high level of sporadic breakdowns.
The matrix shown below indicates what is being controlled under Effective Maintenance and Quality Maintenance, and the method of controlling it, from the equipment management and quality management aspects. This matrix also reinforces the point that the principal feature of Quality Maintenance is keeping quality defects at zero.

6 Activities within Effective Maintenance

6.1 Examples of Activities within Effective Maintenance

Effective Maintenance is a comprehensive programme that brings together a wide range of different maintenance activities under a single umbrella. An example of this is shown below. MP information management, spare-parts management and predictive maintenance are outlined separately.

The Structure of an Effective Maintenance system

6.2 A System for Maximising Production Effectiveness

Figure 6.29 Example of a System For Maximising Production Effectiveness

6.4 Lubrication Management

Approximately 40% of machine elements are subject to rubbing and friction of some kind, and correct application of the right lubricants to these parts serves, among other things, to:

(1) Reduce friction (and hence reduce loss of power)

(2) Ensure smooth sliding movement

(3) Prevent wear

(4) Prevent overheating and seizure

(5) Provide a cooling effect

(6) Remove dirt and debris from rubbing surfaces

(7) Prevent corrosion and erosion

(8) Prevent noise and vibration

Proper lubrication can therefore help to prevent equipment underperformance or failure, as well as increasing productivity and reducing operating and maintenance costs, thereby delivering tangible economic benefits. In practice, wear, deterioration or failure of equipment can often be traced, directly or indirectly, to lubrication problems (see Figure 6.33).

Managing lubrication means managing materials and technology. Lubrication materials management involves purchasing, receiving and storing the required lubricants, paying for them, and disposing of them after use. Lubrication technology management, on the other hand, means observing the four basic rules of lubrication (using the correct lubricant, in the correct amount, by the correct method, and at the correct time), and is therefore applied on the shop floor. Some common problems relating to lubrication are discussed below, together with possible solutions.

Figure 6.33 Equipment Failures

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