Professional Documents
Culture Documents
Professional Maintenance
Professional Maintenance
Contents:
Chapter 1: Introduction
Chapter 2: Methods Tools, and Organization to Eliminate Machine
Breakdowns
Chapter 3: Step by Step Approach to Establish a Planned Maintenance
System
Chapter 4: Shutdown Maintenance
Chapter 5: Establishment of CBM
Chapter 1 Introduction
1.1 Apt Analogy between Human Body and Equipment
1.2 Why do Failures Occur?
1.3 What is the Problem?
1.4 Aims and Objectives of PM
1.5 Better understanding of the Maintenance Issues
1.6 Various Maintenance Activities
1.7 BM, TBM and CBM
1.8 Production Department Activities
1.9 Maintenance Department Activities
1.10 Professional Maintenance Activities
1.11 Structure of Planned Maintenance
1.12 How to Select a Proper Maintenance Method
(1) Flow Chart Based on Production Output, etc.
(2) Based on a Technical Viewpoint
Shame!
16
11
1
1
13
1
6
5
7
Equipment
No
Man
Equipment
Heart
Motor, Power
source
10
Pulse
Vibration
Valves of the
heart
Main valve
11
Blood
pressure
Pressure
Bones
Main body,
Base, Axis
12
Joints
Bearings
Brain
Control function 13
Stomach
Tank, Reactor
Muscle, tendon
Connecting
function
14
Lung
Artery
Main pipes,
Power lines
15
Other organs
Important parts
Vein
Return pipes,
Branch lines
16
Eyes
Instrument
Kidney
Filters,
Strainers
17
Arm
Handle, Lever,
Connecting rod
Blood
Fuel,
Lubrication oil
7
Man
Equipment
Nervous anaphylaxis
Stress concentration
Intoxication
Impurities
Gastec ulcer
Corrosion
Bleeding, Hemorrhage
Oil leakage
Cerebral bleeding
Ectoparasite
Dirt
10
Arrhythmia
Unbalance, vibration
11
12
Heart failure
13
Blow
Dent, Deformation
14
Fracture of a bone
Broken shaft
15
Suffocation
Overcharging
16
Neuralgia
17
Loss of eyesight
Instrumental damage
18
Fever
Seize, Expansion
19
Weakening, Asthenia
Overall deterioration
Cerebral bleeding
Reduce cholesterol
Clean, eliminate foreign body
2. Fracture of a bone
[Preventive measures]
Cripple
Give a treatment as early as possible
Insufficient fastening
3. Arrhythmia
[Preventive measures]
Sudden death
Do not be overloaded.
Proper countermeasures against vibration
Maintenance
team solve
the problem.
10
Time
- New Component
The component
is OK for good
machine
operation
- Cosmetic Defects
- Acceptable Wear and Tear
Acceptabledeterioration limit
-Minor Defects
- Medium Defects
MAINTENANCE
OPERATORS
Nonstandard
parts cause
- Major Defects
machine
losses
Technical people
must set
standards for the
way machine
components
ought to be
12
13
14
problem cannot be
15
16
Total number of
breakdowns
18
Reactive
Money (loosing)
Preventive
Proactive
20
F a ilu r e
ra te
C hance
f a ilu r e
p e r io d
S ta rtu p
f a ilu r e
p e r io d
S p e c if ie d
b re a k d o w n
ra te
U s e fu l
lif e
W e a r- o u t
f a ilu r e
p e r io d
R e d u c t io n o f
f a ilu r e
th ro u g h
m a in t e n a n c e
C a te g o ry
S ta rtu p
f a ilu r e
C hance
f a ilu r e
C ause
D e s ig n /
m a n u f a c t u r in g
e rro rs
O p e r a t io n a l
e rro rs
W e a r- o u t
T r ia l r u n s a t
a c c e p ta n c e a n d
s ta rtu p c o n tro l
P ro p e r
o p e r a t io n
P r e v e n t iv e a n d
m a in t a in a b ilit y
im p r o v e m e n t
C o u n te rm e a su re s
W e a r- o u t
f a ilu r e
M a in t e n a n c e P r e v e n t io n
21
(5) Easy C I L
C : Eliminate contamination
I : Quick inspection
L : Central lubrication system
22
(6) Visualization
23
When some part, if it breaks, has a risk of creating a huge damage, then it
must be placed to expose it to human eyes such that its anomaly can be
detected quickly enough even if such placement looks ugly. (eg. The
rupture of hoses, breakdowns of cables)
Check for
scratches,
cracks, dirt,
etc.
24
25
26
Condition of wear
Cause
Countermeasures
In appropriate or
insufficient lubrication
oil
Review lubrication
method or lubrication
oil
Improve sealing
devices
Thoroughly clean
around the bearing
Invasion of foreign
body
Inappropriate of
insufficient lubrication
oil
Condition of wear
Cause
Countermeasures
Thoroughly wash
around the bearing
Improve the sealing
devices and prevent
foreign body from
invasion
Excessive Wear
Classification
Phenomenon
Cause
Deterioration of tooth
surface wear
Scratching
Classification
Phenomenon
Cause
Deterioration of tooth
surface : wear
Insufficient oiling
Insufficient oiling
Symptoms/conditions
of damages
Anticipated cause
Countermeasures
Periodically supply the
lubrication oil with
proper viscosity.
39
Simplification
30 min.
40
10 min.
41
2 min.
42
30 sec.
43
44
45
Phase 4
Step 7
Step 6
Phase 3
Step 5
Phase 2
Phase 1
Step 2
Step 1
Build a
periodic
Step 4
maintenance
Countermeasures system
Step 3 against weak
points
Establishment of the machine and
lengthened equipof
ment life
maintenance
standards
Maintenance
cost
management
Establishmen
t of
a planned
maintenance
system
Reverse
deterioration
(breakdown analysis)
Reactive
Preventive
Proactive
46
Visible
breakdowns
Potential defects
Prevention of
breakdowns at the
similar process through
horizontal expansion
47
Unexpected
Failure
CMMS
Relevant workplace
Daily/monthly
failure reports
NO
Dealt with locally
Maintenance
department
YES
Restorative action
Emergency action
Emergency action
Restorative action
Action to
restore operation
48
Unexpected failure
report form
CMMS
Section
responsible
Machine history
ledger
Maintenance
calendar
NO
Equipment budget
appropriation
YES
Instigate recurrenceprevention measures
of the failure
Instigate recurrence-prevention
measures of the similar failure
in other areas
Prepare
action report
Recurrenceprevention
action report form
Filing
49
AM :
Autonomous
maintenance
Periodic replacement
and lubrication
Daily cleaning
and inspection
Action
Prompt abnormality
detection
Patrol checking
BM :
Breakdown
maintenance
Request
Regular maintenance
meetings
Recurrence
prevention
Action
Year-round servicing
(maintenance calendar)
Maintenance
TBM :
Planned
maintenance
CBM :
Predictive
maintenance
Mid-term/long-term planned
maintenance (equipment renewal)
Condition, monitoring of
vibration, corrosion, etc.
MP design
Planning/
Design
MP :
Maintenance
prevention
Early management
50
p.d.f.
BM
Time
Time
Replacement period ( I )
Components Lifetime
22 analyzed machines
Before restoration
After restoration
Replaced parts
Replaced parts
12
10
8
6
4
2
0
1.0
0.8
0.6
0.4
0.2
0.0
%
100
80
60
40
20
0
Frequency distribution
month
Accumulated failures
Over-lifetime probability
11 2 23 34 45 5 6 6 7788 99101011
11 121213
13
12
10
8
6
4
2
0
1.0
0.8
0.6
0.4
0.2
0.0
%
100
80
60
40
20
0
Frequency distribution
month
Accumulated failures
Over-lifetime probability
Specified for
replacement
1 2 3 4 5 6 7 8 9 10 11 12 13
1 2 3 4 5 6 7 8 9 10 11 12 13 52
TBM
TBM
Breakdown
occurs !
Replaced before a
breakdown occurs
Few b
period ( I )
Replacement period ( II )
53
CBM
CBM
The degree of
deterioration
Restore
Forced
deterioration
Predict
Natural
deterioration
Check
Check
Predictive
maintenance
Most economical
because the part
can be utilized up to
almost the wear limit.
Time
p.d.f.
Depending on the
diagnosis technique,
there is a risk of
making a diagnosis
error.
Time
Replacement period ( I )
Periodic maintenance
Replacement period ( II )
Predictive
maintenance
54
55
56
2.Measuring deterioration:
Daily inspection patrol checks and five-senses checks during
operation
Periodic inspection part of overhaul inspection during plant
shutdown or shutdown maintenance
3.Predicting deterioration:
Minor servicing emergency measures when abnormal conditions
arise and simple parts replacement
Prompt, accurate reporting of failure and problems
Assistance with repairing unexpected failures
57
58
Improving maintenance
technology and skills
Professional maintenance skills
Equipment repair skills
Inspection and measurement
skills
Equipment diagnostic
techniques and skills
Improving equipment
Autonomous maintenance
support
Planned maintenance (7 steps)
Corrective maintenance
Maintenance prevention
Predictive maintenance
What part?
Practical approach
NO
Possible
Big
NO
Equipment
damage
YES
Equipment
damage
Equipment
damage
Small
TBM
NO
Small
Influence of
production
output
YES
Big
Influence of
production output
Trend
management
Not
possible
BM
Big
Small
Big
Equipment
damage
Big
CBM
Small
IR
BM
TBM
IR
61
Is there any
source of forced
deterioration?
NO
Is there any source of forced deterioration left?
YES
YE
S
YES
NO
Is life reasonably long?
NO
Restoration
&
Improvement
Restoration &
Improvement
NO
YE
S
Life extension
NO
(corrective maintenance)
Is life stable?
YES
YES
NO
NO
IR
TBM
Study of the
deterioration
pattern
YES
CBM
Searching
parameters
Daily maintenance
62
PM
Professional
maintenance
CBM
Autonomous
maintenance
BM
Complete shutdown
maintenance
TBM
Autonomous
maintenance
Planned
Maintenance
Planned servicing
Periodic servicing
Periodic inspection
Periodic checking
Professional
maintenance
Autonomous
maintenance
Partial shutdown
maintenance
Periodical checking
Daily checking and servicing
Continuous monitoring
Alarm
Trend
monitoring
Periodic diagnosis
Interlocks
Opportunity maintenance
OSI
SDI
CM
63
Lubrication control
Spare parts control
Fixed-assets control
Measurement technology
Non-destructive test technology
Equipment diagnostics
Materials deterioration control technology
Erosion control technology
Corrosion control technology
Material damage analysis technology
Material skills training
Specific engineering
technology
Servicing standards
Professional maintenance standards
Autonomous maintenance standards
64
Target
Technique
Normal
operation
Daily
maintenance
Maintenance
Activities
Prevent
Deterioration
Measure
Deterioration
Restore Deterioration
Correct Operation
Correct adjustment
Lubrication
Tightening
Minor Servicing
Overall
Equipment
Effectiveness
(At least 85%)
Periodical Servicing
Maint.
Periodic checking
Periodic
maintenance
Prod.
65
(-Continued)
Preventive
maintenance
Trend inspection
Breakdown
maintenance
Recurrence prevention
Emergency repairs
Simplification
Improve
Reliability
Load Reduction
(Corrective
maintenance)
Improve control
precision
Improvement
Activities
Improve
Maintainability
66
Preventive M.
Normal operation
Autonomous
maintenance
Cleaning
Lubrication
Number
of
incident
s
Tightening
Temperature control
Vibration and sound
control
Techniques
for
prolonging
equipment
life
(precision,
reliability)
Minor repairs
Minor improvements
Techniques
for
predicting
equipment
life
Operational inspection
Planned
maintenance
Condition-based M.
Time-based M.
Predictive M.
Equipment diagnosis
Disassembly inspection
Predictive maintenance
Maintenance prevention
Preventive repairs
Servicing, repair,
improvement
Sporadic repairs
Restoration
and costreduction
techniques
Improvement maintenance
67
(-ve)
Aggregated cost
Cash
outflow
($)
Heavy cash outflow
during downtime
and repair
0
0
Time/usage (hours)
68
(-ve)
Increasing consumption
of fuel, spares, etc.
Cash
outflow
($)
Condition deteriorating
0
Time/usage (hours)
69
Increasing cost as
major components
begin to fail
(-ve)
Cash
outflow
($)
Increasing wear on
moving parts
Plantas new
0
0
Time/usage (hours)
70
(-ve)
Potential
saving
Cash
outflow
($)
0
0
Time/usage (hours)
71
(-ve)
Installation of PM
system
Cash
outflow
($)
0
0
Time (hours)
72
Cost of Installing PM
Cash
outflow
($)
Break even point
0
0
Cash
saving
(ve)
Time/usage (hours)
73