Management&Business: maintenance management

понедельник, 27 июля 2026 г.

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