PLANNED MAINTENANCE - PHASE 4

PREDICTIVE MAINTENANCE

- Estimation of failure means by equipment diagnosis
§ Leakage, cracks, corrosion, irregular sound, irregular temperature, irregular vibration, oil deterioration, electrical
- Estimation of service life and its extension by technical analysis of catastrophic failure
§ Analysis of cross section of failure
§ Analysis of gear material fatigue
§ Analysis of gear tooth surface

PLANNED MAINTENANCE - PHASE 3

TIME BASED MANAGEMENT

- Estimation of service life and time based restoration or replacement - Reduce MTTR
§ KAIZEN of maintainability
- Understanding the irregularity for internal deterioration by using five senses
§ Distinction between those which show signs and those which do not
§ What sign would be considered as leading to failure
§ Why it was not detected in advance?

PLANNED MAINTENANCE - PHASE 2

EXTEND LIFE SPAN

- Extend inherent equipment life
§ KAIZEN of weakness in design
§ KAIZEN in weakness for overloading
- Elimination of accidental failure
§ Improper operation : Fool proofing, training
§ Improper repair : skill identification, gap analysis, training
- Restoration of exterior deteriorationDust ,Corrosion, vibration

PLANNED MAINTENANCE - PHASE 1

INCREASE MTBF

- Restoration of unattended deterioration
(Rectification of revealed defects)
- Elimination of forced defects
> Establish original equipment or basic conditions
> Maintain the right operating condition

PLANNED MAINTENANCE ACTIVITIES

FOUR PHASES

- Phase 1 : Increase MTBF
- Phase 2 : Extend the life span
- Phase 3 : Time based Maintenance
- Phase 4 : Predict failures

TYPES OF MAINTENANCE

· Maintenance activities to prevent / fix failures
o Preventive Maintenance
§ Time based maintenance
– Daily checks, Periodic checks, Periodic servicing
§ Condition based maintenance
– Rotating equipment diagnostic
– Static equipment diagnostic
o Breakdown Maintenance
· Improvement activities to expand life span / to shorten maintenance time / to avoid maintenance
o Corrective maintenance
o Maintenance prevention

PLANNED MAINTENANCE

GOAL:

To focus on preventive actions to eliminate equipment failures / breakdowns in order to ensure availability & reliability of equipments &minimize cost of maintenance.


APPROACH:

1. Maintenance activities
- To prevent failures
- To fix failures

2. Improvement activities
- To extend life span of parts
- To shorten maintenance time
- To avoid maintenance

METHODOLOGY:

Step-1 : Support & guidance of JH activity.

Step-2 : Evaluation of equipment failure / breakdown status & understand situation.

Step-3 : Reverse Deterioration & correct weakness

Step-4 : Build an information management system

Step –5 : Build a periodic maintenance system.

Step-6 : Build a Predictive maintenance system
.
Step-7 : Evaluate the Planned maintenance system.