Planned Maintenance Pillar Workshop

Planned Maintenance – Introduction

General:

Provide an overall understanding of Planned Maintenance
Facilitate the site in developing and refining the PM plan
Identification of additional training requirements

Develop an understanding of:

Objectives of the Planned Maintenance Pillar
The support required for Autonomous Maintenance, T&E, and EM Pillars
The objectives and approach of each of the PM elements

Prepare:

Develop a 3 Year Pillar Master Plan
Detail for each of the 8 PM elements
Pillar Goals, Targets, and KPI’s

Presentation:

Presentation of workshop results to Site Steering Committee

TPM Health Check

Must be able to plan, organize, lead and control;
Planning the work by predetermining the expected quality and quantity of output for every job;
Organize the work by specifying the appropriate ways and means to perform each task;
Leading and influencing others to engage in work behaviors to achieve the desired results;
Controlling the work by:
- selecting and training qualified individuals;
- overseeing the actual job performance;
- verifying that the output meets the expectations.

Purpose

To establish and maintain optimal equipment and process conditions, cost-effectively and efficiently.

Plan

PM and AM are clearly defined. Both maintain the equipment with shared responsibilities.
Time-Based Maintenance (TBM) and Condition-Based Maintenance (CBM) is being selectively used.
Specialized maintenance techniques such as lubrication control and root cause analysis are being used.
Reliability, maintainability, and availability are being measured.
Corrective maintenance is pursued and utilized in the creation of MPs.
Maintenance equipment is under control.
Data concerning downtime, man-hours, MTBF, MTTR, etc is being analyzed.
CMMS is being effectively utilized.
Equipment diagnosis techniques are studied and used.
Maintenance costs are understood and controlled.

The 6 steps for effective maintenance

Step 1. Evaluate and understand current conditions

Prepare or update machine log
Evaluate and prioritize the equipment
Rank failures
Understand the failure situation and set maintenance goals

Step 2. Restore deterioration & correct weaknesses

Help operators restore the equipment
Correct weaknesses and lengthen equipment life using focused improvement methods
Prevent recurrent major failures

Step 3. Build an information system

Build a failure data management system
Build a system for controlling parts and materials
Build a system for controlling technical information

Step 4. Build a periodic maintenance system

Select equipment and components for periodic maintenance
Prepare maintenance plans
Formulate periodic maintenance standards

Step 5. Build a Predictive maintenance system

Select key equipment for predictive maintenance
Introduce equipment diagnostics
- Vibration, Temperature, Lubricant sampling
Roll out to other equipment

Step 6. Evaluate the maintenance system

Evaluate improvement on
- reliability
- maintainability
- maintenance cost savings
Review the whole system

Agenda

The concept of Planned Maintenance is designed to lower costs by conducting maintenance efficiently and eliminate breakdowns by enhancing equipment effectiveness.