PLANNED MAINTENANCE – PM CHALLENGING THE TEAM TO ZERO UNPLANNED MACHINE BREAKDOWN
Planned Maintenance is defined as maintenance activities performed on a pre-determined schedule of activities. The basic responsibility of maintenance is not to repair breakdowns but to analyze what had caused the failure by taking measures to prevent the recurrence of the problem. Through the Planned Maintenance activities, we can improve the reliability of the equipment by letting the team take up the challenge to zero machine breakdown and also to improve maintenance efficiency. Build the maintenance system and cost reduction strategies by improving the machine’s life cycle by understanding the concept of Planned Maintenance, so can achieve reliable equipment and maintenance skills to carry out the PM activities.
- What are the basics of planned maintenance?
- Identify time based maintenance ineffectiveness
- Define why equipments deteriorate.
- What changes to make to improve reliability
- How to gain productivity through small changes in thinking.
- Developing task lists for different equipments.
- Prevent and extending equipment components useful life.
- Using the P-F curve to choose inspection frequencies.
- Drive towards zero unplanned equipment failures.
WHO SHOULD ATTEND
Quality Assurance, Quality Control, Production, Process, Managers, Executives, Engineers, Supervisors, Technicians and anyone who would like to improve their knowledge in Maintenance.
Also, for those who are in operations would like to acquire an understanding of how the quality of the maintenance activities affects their equipment functions if wrong type of elements used.
Planned Maintenance from a Business perspective
- Introduction to maintenance
- Maintenance objectives.
- Impact of maintenance
- Eight Pillars of Planned Maintenance
- Four Phases of Planned Maintenance
Type of Maintenance Strategies
- Preventive Maintenance
- Predictive maintenance (PdM)
- Vibration Monitoring
- Tribology Analysis
- Breakdown Maintenance
- Corrective Maintenance
Major Plant Losses cause Machine Deterioration
- Understand Sporadic Losses
- Understand Chronic Losses
- 6 Major Equipment’s Losses
- Equipment Failure.
- Setup and Adjustments.
- Idling and Minor Stops.
- Reduced Speed.
- Process Defects.
- Reduced Yield.
Failure Mode Analysis Improve Lengthening Equipment Lifetime
- What We Include as Breakdown
- Understand Functional failures.
- Analysis Failure Mode.
- What causes Failure Mode
- Evaluate Failure Effect
Planned Maintenance Roadmap Reliability
- Step-1 Analysis of the difference between the basic and use condition
- Understand the issues (Pareto Analysis, 5W-1H, 5 why Analysis,)
- Step-2 Improvement of the difference between the basic and use condition
- Maintain basic equipment condition (Clean, Replace panels, mounting hardware)
- Step-3 Preparation of standards for basic and use condition
- Maintenance schedules, Inspection Checklist, Trouble shooting guides
- Step-4 Extension of service life
- Execute corrective maintenance (Improve, Redesign, Use higher technologies)
- Step-5 Improvement of inspection and maintenance efficiency
- Research of deterioration, Detection of internal deterioration, Activities to reduce breakdown maintenance
- Step-6 Overall equipment diagnosis
- Revise maintenance standards and enhance maintenance skills and technologies
- Step-7 Use of equipment to its limits
- Develop diagnostic techniques (Predictive maintenance)
Root cause analysis
- Introduction RCA
- What is 5 Why
- Origins of Why Why analysis.
- Benefits of the 5 Whys
- 5 Whys Analysis in Action
- What is a Cause-and-Effect Diagram?
- Benefits of Using It
- Cause-and-Effect Diagram
- Identify and Define the Effect
- Identify Causes Influencing the Effect
Measuring the Effectiveness of Maintenance Activities
- Measuring maintenance performance
- Overall Equipment Effectiveness
- Equipment Reliability analysis