Planned Preventive maintenance by Umer javed Butt

1. Planned Preventive Maintenance

2. Key Points’
>Planned Preventive Maintenance
>Predictive Maintenance
>Previous Tendencies based Analysis
>Parts categorization upon data analysis
>Division of parts/sections in daily, weekly and monthly
basis
>Operator involvement/ownership
>Autonomous Maintenance
>OEE (overall equipment effectiveness)
>6S
>TPM (Total Productive maintenance)
> EMP (Equipment Maintenance plans)
>Proactive Maintenance Technique

3. Main goal will be to work on planned preventive maintenance rather than reactive maintenance
Preventive maintenance is done with schedules in hand and could be planned and required spares
could be ordered as per plan .Preventive maintenance main activity can be divided into C-O-T
C -Cleaning of equipments .Very Important as majority of break downs happens due to lack of
proper cleaning
O - Oiling or topping for gearboxes , chain and sprockets , moving parts , lubricating systems .
T -Tightening of all fasteners which have loosened in operations or which could not be done in
course of production.
Normally for bakeries a day is fixed in a week for preventive maintenance. Maintenance jobs are listed in
the course of the week and all critical repairs, replacement and modifications are done on preventive
maintenance along with regular maintenance job (COT)
Preventive Maintenance Tools in CMMS
Computerized Maintenance Management Systems (CMMS) are
1) PM Task Generation
2) PM Task Schedules.
3) PM Inspections

4. The role of preventive maintenance
Preventive maintenance is important for the following areas:
 Operational efficiency.
 Functional performance
 Food safety
 Documentation and traceability. .
 Repair costs. .

5. .
o
Applications of Preventive Maintenance
There are many applications of Preventive Maintenance in a wide variety of industries
such as:
 Performing calendar-based maintenance on air conditioning units on a university campus
 Scheduling consistent maintenance on assets critical for production
 Meter-based PMs for maintenance of material handling equipment based on utilization
 Scheduling PM tasks in preparation for audits
.

6. Predictive Maintenance
this methods utilizes prior diagnosis of any aberration from ideal operations with help of sensing
equipments through Inspection.
Heat
Noise
Smell
Equipment used are Multimeter , Ultrasonic equipments , Vibration analyzer , Decibel Meters ,Infra red
equipments .Now days PLC based systems are common hence system health can be checked through
various software .

7. We can categorize the parts/sections on their importance and uses basis
Category 1: Critical Plant Equipment•
Equipmentselectedbythe plant as critical plant equipmentthat affectseitherthe entire plant or one
of the KeyValue Streams.
Category 1A: TPM PilotEquipment•
Category 1A Equipmentis a strategic sub-setofCategory 1.
These will be the “pilot” equipmentstrategicallyselectedasmost important to the plant, where TPM
effortswill initiallybe focusedin the plant. It is recommendedtofocus on 3-6 piecesofequipmentas
Category 1A.
Category 2: KeyEquipment•

8. This equipmentisconsideredto have limitedor minimal impact to your overall operations.Factors to
considerinclude:•Critical equipmentwithsome back-up capabilities•May shutdown a portion of a
key value stream. •Non-capacity constrained•May have an limitedimpact on other strategic
imperatives(i.e.:Quality,conversionloss,financials,etc) Category 3: Non-Critical Equipment•this
includesall non-critical equipment•Non-critical equipment•Auxiliaryequipment
Further we separate these parts in daily, weekly and monthly maintained basis
Total Productive Maintenance was developed by Japanese companies, trying to
extend the existing concept of Total Quality Control (TQC) with the ideas of
preventive and predictive maintenance programs.
Since TPM gives operators much more responsibilities, a dedicated training is
required as well as some modifications on the machines to ease operations of
cleaning and maintenance. This will significantly increase the operators’ skills level
and helps them better understand how to maintain and even improve the equipment.
TPM
>No breakdowns
>No small stops or slow running
>No defects
>No accidents
Maximum efficiency of equipment

9. TPM focuses
>Autonomous Maintenance
>Planned maintenance
Quality Integration
Focused Improvement
Early equipment management
6S
Operator’s Education Starts with the Six S:
5S Seiri, or in English; Sort, Clearing
5S Seiton, or in English; Straighten, Simplify, Set in order,
5S Seiso, or in English; Sweep, shine, Scrub, Clean and Check
5S Seiketsu, or in English; Standardize, stabilize
5S Shitsuke, or in English; Sustain, self discipline, custom and practice
The 6th “S”; Safety
Key points.
Old Attitude “I operate,you fix.” “Ifix,you design.” “Idesign,you operate.”

10. TPM Attitude “We are all responsible forour equipment.”
. A Daily walk –around checklistis developedandperformedconsistentlyfora periodof 1
month. Operator and technician responsibilitiesneedtobe clearlydefined.
A Visual Management systemis inplace to capture issuesidentifiedduringPre-Flight.Daily
Walk Around.An Accountability processesestablishedtoaddressidentifiedissuesina timely
manner.
What Actions Are Expected from an Operator Performing
Autonomous Maintenance?
Autonomous maintenance requires operators to develop and master certain skills:
1. Detect abnormalities and make improvements;
2. Understand the functions and the components of the machines and detect the
causes of abnormalities;
3. Recognize possible quality issues and identify their causes.
AUTONOMOUS MAINTENANCE GIVES
OPERATORS FREEDOM AND
RESPONSIBILITY

11. Autonomous maintenance (AM) is performed by the operators and not by dedicated
maintenance technicians. It is a crucial component of the Total Productive
Maintenance (TPM). The core idea of autonomous maintenance is to provide the
operators with more responsibility and allow them to carry out preventive
maintenance tasks.
According to conventional maintenance programs, a machine can run until it breaks or
reaches its maintenance date. The maintenance department is then responsible for
handling/fixing it. In contrast, autonomous maintenance allows machine operators to
carry out directly simple maintenance works (lubrication, bolt tightening, cleaning and
inspection) to prevent breakdowns and react faster if a certain failure has been
detected.
.
1. Education
2. Initial Cleaning and Inspection
 Leak detection;
 Control of loosened bolts;
 Lubrication;
 Detection of non-apparent cracks; contamination rate decrease of oil or other fluids;
 Correction of defective items;
 Removal of material rests from oil or water;
 Removal of dust and dirt and therefore reduction of paint corrections;

12.  Suppression of conductibility of trouble in the electric manufacturing due to oil deposits
or dust on the contact points;
 Suppression of electrical incidents related to conductivity contact points covered with
oil deposits or dust;
 Elimination of micro-stoppages due to accumulation of dust, waste;
 Prevention of fire in the waste and dust accumulated in inaccessible places;
 Better precision adjustments especially when changing production levels.
3. Eliminating Contamination and Inaccessible Areas
A maintenance manager should take into account the following possible solutions:
 Maintain cleaning standards. .
 Achieving lasting cleanliness by avoiding soiling.
 Promoting cleanliness
 Encouraging operators to keep order
 Operators should be shown how to facilitate the planned inspections by
eliminating any inaccessible zones.
4. Develop Standards for Cleaning, Lubrication and
Inspection
.
In this case, two complementary methods should be followed:

13.  In case of non-critical machines, operators can be trained in-house to follow the
established general standards and then given the opportunity to settle their own rules,
led by an experienced technical maintenance engineer.
 In case of critical machines, a special working group, dedicated to maintenance
methods and production, can be created.
The final outcome of this phase is the established standards, which are also the best
evidence for the successful implementation of autonomous maintenance at a plant.
5. Inspection and Monitoring
 Checking lubrication levels;
 Locating leaks;
 Tightening loose bolts;
 Identifying possible mechanical problems as cracks, wear, etc ...;
 Performing mechanical adjustments: tension measurement, regulate sensors, micro
switches, etc…
6. Finalize Standards
The last step for a successful implementation of autonomous maintenance is to
finalize all provisional standards and establish a process for autonomous
maintenance.
 Extending the life of assets, and increasing equipment uptime

14.  Reducing manual data entry
 Decreasing paperwork with mobile maintenance capability
 Increasing productivity and efficiency
 Improving audit compliance with extensive documentation
SIMPLIFIED ROADMAP
An excellent way to get a deeper understanding of TPM is to walk through an
implementation example. This section provides a step-by-step roadmap for a
simple and practical TPM implementation.
 Step One – Identify Pilot Area
 In this step the target equipment for the pilot TPM program is selected.
There are three logical ways to approach this selection.
 >Easiest to improve
 >Bottleneck
 > Most Problematic
 Step Two – Restore Equipment to Prime Operating
Condition
 > Photograph
 > Clear Area
 > Organize
 > Clean Up
 > Photograph
 > Checklist
 > Audit
Next, an Autonomous Maintenance program should be initiated. Strive to
build a consensus between operators and maintenance personnel on
which recurring tasks can be productively performed by operators. In
many cases, light training will be required to bring up the skill level of
operators.
> Inspection Points
> Visibility
> Set Points

15. > Lubrication Points
> Operator Training
> Create Checklist
> Audit
Address Major Losses
Equipment Maintenance Plans
The Equipment Maintenance Plan, or EMP as it is commonly called, is a document, in
table format, that is used when developing the tasks needed to properly maintain
facility, plant or process equipment. The EMP helps lead the person or persons
developing the required maintenance tasks by ensuring that the development is done
consistently for all equipment. Each EMP should include one or more maintenance
tasks designed to ensure the continued operation and maintenance of an equipment
item, process or system. Each of these tasks has the following characteristics:
 A descriptive title for each maintenance task to be performed
 A frequency assigned for performing of each task
 Assignment of a specific craft or workgroup and the number of each craft or
workgroup required to perform the task
 Equipment condition required for performance of the task (i.e. running or shut
down)
 Type of Work – Preventive Maintenance (PM), Predictive Maintenance (PdM),
Corrective Maintenance (CM), Situational Maintenance (SIT), etc.
 Procedure number – Unique identifier for the task, or file name if linked to another
document that gives the individual task instructions
 Estimated time to perform the task
 Special tools, materialsand equipment required to perform the task
The EMP can also provide the following additional planning and budgeting information if
set up properly in a spreadsheet format:

16.  Annualized hours for performing the task
 Annualized hours for shut down of the equipment during performance of the
task
 Annualized hours for performance of the task by craft
Each EMP consists of the following defined sections that contain specific information
(See example EMP at the end of this paper):


17. 
1. Autonomous Maintenance
2. Focused Improvement
3. Planned Maintenance

18. 4. Quality management
5. early/equipment management
6. Education and Training
7. Safety Health Environment
8. Administrative & office TPM
Creating a Maintenance Checklist for Your Facility
The first step that goes into proper preventive maintenance is creating individual
checklists for each
of the facilities you manage. A one-size-fits-all checklist is not recommended if
you are in charge of
several facilities because they often have different assets and buildings. Create a
checklist for every
building in your facility. Start from the top of the building, writing down each part
that requires
maintenance and breaking the process into several actionable steps. Include a
checkbox alongside
each step of each maintenance process, as well as a blank space for the
employee to write the date
when maintenance was performed.
Steps to World-Class Manufacturing Maintenance
Given the complexity of the maintenance process, there are several steps you
need to take in order
to achieve an efficient maintenance plan for your facility. We have broken down
this process into 4
essential steps:

19. 1. Gather Data and Calculate Downtime Costs
2. Determine the Value of Maintenance
3. Identify Maintenance Tasks.
4. Schedule Maintenance Tasks
Building Maintenance Windows into Production
Plans
Preventative maintenance can take time, from a few hours to days depending on
the complexity of
the process. This can greatly impact product, as production units have to stop
working and make the
equipment available to the maintenance crew. In order to prevent a decrease in
productivity,
manufacturing maintenance managers should build maintenance windows into
production plans.
For example, it could be agreed that on Wednesday morning Production Unit 1
will stop production,
and make the equipment available to the maintenance crew for, say, five hours.
During this
maintenance window, the maintenance crew can successfully assign as many
people as required to
complete the planned maintenance fast and get the equipment back to work until
the following week.
Creating tables or checklists in which maintenance windows are built into
production plans will not

20. interfere with general productivity of the facility. Usually, the use of a CMMS
system provides a
relatively easy solution to scheduling and planning preventative maintenance,
helping reduce
downtime cost to a great extent.
Equipment preventive maintenance planning tips
1. Use categories & hierarchies to make equipment management easier
2. Combine simple maintenance tasks done on several equipment into one
work order
.
3. Estimate future spare parts & supply needs
4. Check for maintenance technician availability
.
5. Outsource some maintenance work
6. Review the plan & check performance
7. Understand the difference between work time & idle time
:
Consider a continuous monitoring system. Continuous monitoring is the application of
dedicated devices for collecting predictive maintenance-style data to aid in a condition
monitoring program. With each passing year, this technology gets cheaper, and the desire
for more complex and more robust monitoring gets larger.
Build a strong relationship with operations. To get better at maintenance, you must get
better at building a positive relationship with operations. To achieve maintenance
excellence, you must have an excellent relationship. This means having maintenance in full
alignment with the larger goals of your operations and your company.
Quantify the cost of a functional failure mode. What is the real cost of a failure?
Unfortunately, we don't know until after the failure has occurred - and reliability is about
avoiding the failure.

21. Develop standard maintenance procedures. Plants often fail to see the importance of
having well-written procedures for most tasks. This article discusses the importance of
having good procedures and presents the details needed to develop well-written standard
maintenance procedures.
Manage assets by criticality. Through proper construction of the criticality analysis model,
reliability engineering will be able to illustrate what reliability enhancements must be made
to manage criticality, thus improving their ability to manage assets by criticality.
Teach operators the “Should-Actual Five-Whys” method. Operators in a reliability-
focused culture should have a questioning attitude and be very observant. The inclusion of
the S-A-5Whys tool in their skill set will benefit the organization by the early identification
and resolution of problems, leading to increased asset reliability.
Apply the correct maintenance strategies. True reliability is achieved when the most
cost-effective methods are applied to the assets in your plant, thereby maximizing reliability
with the minimum total cost to the business.
Benchmark your lubrication program. Benchmarking provides a much-needed scorecard
for areas of lubrication that may not be obvious or often considered for improvement. It is
true that we “don’t know what we don’t know”.
Detect machine problems early. This massive list of inspection items will allow you to
detect problems early, and hopefully eliminate downtime and/or reduce maintenance costs.
Remove process bottlenecks. If your process bottlenecks are linked closely to the
maintenance and reliability of your equipment, it is most likely you have a highly reactive
maintenance organization. To move from a primarily reactive regime, significant focus must
be placed on developing and deploying systems that move the organization toward being
proactive.
Optimize PM tasks. Unfortunately, most preventive maintenance tasks lack the detail that
will provide quantitative data for equipment history, and they are written without considering
failure modes. The solution is to practice Preventive Maintenance Optimization (PMO),
using all aspects to write PM procedures that are value added, comprehensive, repeatable,
organized, and specify a correct duration and interval of execution.
Put maintenance checklists to use. While most groups will say they have checklists,
requiring their use and the accountability are often major factors for success. In your
organization, what processes do you have in place to ensure that people use maintenance
procedures and checklists?

22. Avoid the 5 biggest risks. Asset management is an integrated approach to optimizing the
life cycle of your assets, beginning at conceptual design, through to usage,
decommissioning and disposal. By acknowledging and paying attention to these five
primary risks to effective asset management, you can put in place plans to mitigate the
effects these might have on their program.
Give maintenance technicians equipment ownership. How do you strike a balance
between equipment ownership and building the skills through cross training, and having the
ability to get the work done all the time? Is it based on the culture of the organization?
Work towards zero failures. Experiences and data show that zero failures are possible in
a maintenance program. As someone once said, “If you think you can’t, you’re probably
right. If you think you can, you’re probably right.”
Manage the change process. The most difficult but most beneficial aspect of leading a
maintenance and reliability improvement effort is managing the change process in
organizations. The behavior change process from a reactive state to a proactive state is a
challenging transition for any maintenance program
Introduce Proactive Maintenance Techniques
In this step, proactive maintenance techniques are integrated into the
maintenance program (thus introducing the TPM concept of Planned
Maintenance).
First, identify all components that are candidates for proactive maintenance:
Components that Wear Identify and document all components that undergo wear
(these should have been established as inspection points in Step Two). Consider
replacing wear components with low-wear or no-wear versions.
Components that Fail Identify and document all components that are known to
regularly fail.
Stress Points Consider utilizing thermography and/or vibration analysis to provide
additional insights as to equipment stress points.
Next, establish initial proactive maintenance intervals:
Wear Based For wear components, establish the current wear level and a baseline
replacement interval (in some cases replacement may be triggered early by
an Autonomous Maintenance inspection as established in Step Two).

23. Predicted Failure Based For failure-prone components, establish a baseline
(predicted) failure interval.
Time Based Create a baseline Planned Maintenance Schedule that schedules
proactive replacement of all wear and failure-prone components. Consider using
“Run Time” rather than “Calendar Time” as the interval time base.
Work Order Based Create a standard process for generating Work Orders based on
the Planned Maintenance Schedule.
Next, create a feedback system for optimizing the maintenance intervals:
Component Log Create a Component Log sheet for each wear and failure-prone
component. Record every instance of replacement, along with information about the
component condition at the time of replacement (e.g. wear amount, “component
failed”, “no observable issues”, etc.).
Monthly Audit Perform a monthly Planned Maintenance audit: a) verify that the
Planned Maintenance Schedule is being followed, b) verify that the Component Log
sheets are being maintained, and c) review all new entries in the Component Log
and adjust maintenance intervals where appropriate. Keep audits positive and
motivational (treat them as a training exercise).
Maintenance Interval Anytime there is an unscheduled component replacement,
consider adjusting the maintenance interval. If the component is not on the Planned
Maintenance Schedule, consider adding it.
Component Analysis Consider plotting data over time from thermography and
vibration analysis to expose emerging problems and issues.
Conclusions and Findings on PM
>Shift to Preventive Maintenance from Reactive maintenance
>Pre plan Maintenance schedules on all production lines by coordinating with
Planning and Production teams
>Divide plans on daily, weekly and monthly basis

24. >Division of plans can be done on parts basis, section basis, line basis, due date
basis depending on the schedule mutually decided between preventive
maintenance and production planning department.
>Maintenance plans can planned on day and night shifts or weekend holidays
so that the regular production plan will not disturbed
>Mechanical equipment lists will be made in different categories depending
upon their usage and importance in the plant.
>Implement TPM
>Implement Autonomous maintenance and involve operator in this plan
>EMP implementation
>Maintenance planning software will be introduced to keep in record all the
plans and pre plan all the maintenance schedule
>checklists will be displayed on all sections and major parts to display all the
preventive records
>Proactive Maintenance will be implemented
>By checking the previous six month maintenance record we can make a list of
parts and sections which are mostly and repeatedly repaired or replaced to
keep a close check on these parts and sections.
>Implementation of 6S
>Implementation of OEE
>UN wanted and UN planned stoppages of lines will be minimized leading to
optimum preventive maintenance