8 Elements Approach – Planned Maintenance Structure

 

Total Productive Maintenance (TPM), a system where workers and operators help clean, check, and fix their own machines to stop breakdowns before they happen. It focuses on team-based upkeep, safety, and making daily work run smoothly.

Key Parts of Total Productive Maintenance

Autonomous Maintenance: Operators do simple daily tasks like dusting, oiling, and looking for loose parts on their own tools.
Planned Maintenance: Technicians use a calendar to fix or swap parts based on how machines wear down over time.
Focused Improvement: Small groups work together to solve hard, repeat machine problems using step-by-step ideas. 

Main Goals

Zero Breakdowns: Keep machines running without sudden stops.
Zero Defects: Stop bad products from being made due to tool errors.
Zero Accidents: Make the workspace safe for everyone. 

TPM activity in which the specialized maintenance department shifts the maintenance focus:

• from breakdown maintenance (BM) to preventive maintenance (PM);

• from corrective maintenance (CM) and time-based maintenance (TBM) to predictive maintenance (PdM) or condition-based maintenance (CBM);

• while reducing maintenance costs and supporting the Autonomous Maintenance program.

Four phases approach for Zero Breakdown

• Phase 1. Reduction in the irregularity of failure frequency
  • Restoration of deterioration left unattended for a long period to the original state
    • Handling the latent defects
  • Elimination of forced deterioration
    • Establish basic conditions
    • Defining and keeping with operating conditions

• Phase 2. Extension product life expectancy
  • Improving weak points in the design
    • Improving weakness in strength and accuracy
    • Selecting the components meeting the requirements
    • Improving weakness for excessive loading
  • Elimination of incidental failures
    • Improving operation and maintenance skills
    • Countermeasures to prevent improper operation
    • Countermeasures to prevent improper repair
  • Restoration of external deterioration

• Phase 3. Time-based restoration of deteriorated portion to the original state
  • Time-based restoration of deterioration
    • Prediction of service life
    • Time-based inspection and testing standards
    • Time-based replacement criteria
    • Improvement of maintainability
  • Detection of the sign of abnormality inside the equipment through senses
    • One which shows a sign and one which does not show any sign
    • What kind of sign can be seen before the abnormality occurs?
    • How can we detect the sign?

• Phase 4. Prediction of service life
  • Prediction of service life through equipment diagnosis technique. Technological analysis of catastrophic failure
    • Analysis of fracture Plane
    • Analysis of material fatigue
    • Analysis of gear teeth etc.
    • Countermeasure to retain a longer service life
    • From the prediction of service life to the time-based restoration of deterioration

Equipment Model & Parts Model

7 step activities for Planned Maintenance and Autonomous Maintenance

PM 8 Elements. 7 – Step Deployment. Part 1

Part 2

Part 3

Part 4

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