Module III bu pom notes

8/6/2019 Module III bu pom notes

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Asst Prof Arvind Gajakosh

BE, MBA, NET


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Machines, equipment etc are going to havedeterioration with age. They will have the effectof wear and tear, temp, vibrations and looseness.

In addition to these there will be accumulation ofdust, rusting of parts over time.

The process of deterioration is reflected in

Inability to the m/c to take up specified load.

Inability to the m/c to produce quality goods.

Reduction in the useful life of the variouscomponents of the m/c parts.

Increased hazards to the safety of employeesworking on or near the m/c.


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Maintenance may be understood as a set of

activities which help keep plant, machinery &

other facilities in good condition.

Loses resulting from breakdowns Cost of repairs

Reduced life of the equipment

Effect on other machines

Added set up costs Loss of materials

Idle wages to workers

Increase in work in progress investment


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Ensuring maximum plant availability by preventing

unexpected breakdowns & by reducing shutdown

periods.

Maintenance of equipment at its ratedproductivity and original accuracy.

Minimization of wear & tear to increase the

longevity of the equipment.

Elimination of unsafe conditions that causeaccidents there by ensuring safety of workmen.

Increase in productivity of machines through

improvements and modifications made during

scheduled overhauls(take apart).


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Breakdown or corrective maintenance

Preventive maintenance

Predictive maintenance

Routine maintenacne

Breakdown or corrective maintenance

Maintenance work performed to restore an

equipment back to its acceptable performance.

Since no attempt is made to prevent the

occurrence of the fault b/d maintenance is also

called as operate to fault maintenance.


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Preventive maintenance

Repair of machines at planned intervals so that

sudden breakdowns could be prevented and costly

down time avoided. This work can be done during off shift hours or

holidays.

Maintenance work performed at predetermined

intervals, or to other pre set criteria with an aimto reduce the possibility of the equipment not

meeting an acceptable performance.


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Predictive maintenance

One of the newer type of maintenance that may

be anticipated to gain increasing attention is

called predictive maintenance. Conditions can be measured periodically or on a

continuous basis.

This will allow an extension to the service life

without fear of failure. Routine maintenance

This includes activities such as periodic inspection,

cleaning, lubrication & repair of production

equipments.


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TPM is a mgmt system for optimizing the

productivity of manufacturing equipment through

systematic equipment maintenance involving

employees at all levels. The goal of TPM is to markedly increase production

while at the same time, increasing employees

morale & job satisfaction.


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Aim at the creation of collective culture relating to

the attainment of maximum efficiency throughout

the production process.

Use the sys so as to prevent losses & to reach theZero accident, Zero defect & Zero

breakdowns, in the manufacturing process.

Involve the entire work force from bottom to top.

Obtain zero losses by integrating the activities ofteams with the production system.


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TPM eliminates 6 big losses which are as listed below Breakdowns which can result in long, expensive

repairs.

Set ups & changeovers which can take much longer

time than needed. Idling & minor stoppages which are hard to quantify

and add up to big losses.

Reduced equipment speed which results in gradual

deterioration of equipment cycle times.

Defects & rework which results in quality losses &

unhappy customers.

Start-up losses which can take much time to get

steady state after a change.


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Increased equipment productivity

Reduced equipment downtime

Increased plant capacity

Lower maintenance & production cost

Approaching zero equipment caused defects

Improved return on investment

Ensuring pollution control measures

Better understanding of the performance of

equipments.


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MTBF = Total Running Time

Number of Failures

Speed (%) efficiency = Actual cycle time * 100

Design cycle time

Quality (%) efficiency = Good parts produced * 100

Total parts produced


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OEE% = Availability * Performance * Quality

Availability = Operating time

Available time

[Operating time = Available time - idle time]

Performance = Ideal cycle time * Piece produced

Operating time

Quality = Good pieces

Total pieces


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5 S

Jishu Hozen

Kaizen

Planned Maintenance

Quality Maintenance

Training

Office TPM

Safety, Health & Environment


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The different S are as follows:

Serie (sort)

Seiton (systematise organize)

Seiso (sweep clean)

Seikersu (standardize)

Shitsuke (self-discipline)


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Serie (sort):

This means sorting & organizing items as per the

frequency of usage. If the items are used once per

year they can be stored away from the work place. If the items are used once per month or once per

week, they can be stored together but off-line.

If the items are used daily, they should be stored at

the work place itself.


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Seiton (systematise organize)

The items should be stored in an organized way.

There should be place for each item & each place is

assigned with only one item. Name plates andcoloured tags may be used for easy identification.

Seiso (shine the work place): this means that the

work place should be cleaned such that it is free frmburs, grease, oil, waste,scrap, etc.


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Seiketsu(standardization): the employees should

decide the standards for keeping the work place,

machines, assails in neat and clean condition.

The standard should be inspected randomly.

Shitsuke(self-defence): this means that the

employees should treat 5 S as their way of life

and develop self discipline by way wearing

badges, following work procedures, punctualityand dedicating themselves to the organization,

etc.


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kaizen means change for the better in Japanese.

The foundation of Kaizen model consists of five

elements which are : Team work, Personal

discipline, Improved morale, Quality circles &suggestions for improvement.

Kaizen focuses on zero losses, cost reduction in all

resources, improvement of overall plant

effectiveness.


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Planned maintenance aims to have trouble free

machines & equipments to produce defect free

products to fully satisfy customers requirements.

This planned maintenance is classified into

breakdown, preventive, & predictive maintenance.


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Quality maintenance aims to maintain the

equipments in good operating condition such that

highest quality products are delivered to customers

through defect free manufacturing.


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Training is an important pillar in TPM which

emphasizes educating operators to upgrade their

skill. It is not sufficient to know only know-how

but they should also learn know-why.


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This a mainly aims to improve the productivity &

efficiency in the administrative functions by

indentifying & eliminating losses in them.

This is achieved by analyzed processes &procedures for enhanced office automation.


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These things aim to have zero accident, zero

accident, zero health damage and zero fires.

One can achieve these things by creating a safe

work place and a surrounding area that is notdamaged by the processes and procedures.

The awareness among employees can be created

through competitions like, safety slogans, quiz,

drama, posters, etc. which are organized at regular

intervals.

Module III bu pom notes

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