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Maintenance english

Shiju Nesamony
Shiju Nesamony

This document provides an overview of maintenance functions for manufacturing organizations. It discusses the responsibilities of maintenance engineers, the different types of maintenance including breakdown, preventive, and autonomous maintenance. Autonomous maintenance involves operators performing basic cleaning, inspection, and maintenance tasks on equipment. The document outlines the steps to implement autonomous maintenance, including preparing, cleaning equipment, identifying abnormalities, and eliminating issues found. It aims to educate on best practices for maintenance to minimize breakdowns and keep equipment functioning properly.

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The Essentials - Maintenance HASH MANAGEMENT SERVICES LLP CHENNAI PH: 91766 13965
Overview The Essentials series from Business Sense is an initiative to empower the students(freshers) and professionals in performing more efficiently and effectively in the organization This document is a part of the Certified Manufacturing Professional course offered by Business Sense This course is aimed at bridging the gap between the institutions and the industry by providing the fundamentals of manufacturing management which are not offered by any of our institutions/curriculum This course would immensely benefit students and professionals who are joining manufacturing organizations For more details, please visit www.businessense.in At Business Sense, we help clients through consulting engagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools. We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply Chain Re-engineering. You can subscribe to our bi-weekly newsletter here. Follow us: Copyright of Hash Management Services LLP www.businessense.in
Contents Section 1 Introduction and Basic Processes Section 2 Autonomous Maintenance Section 3 Pictorial Representations Copyright of Hash Management Services LLP www.businessense.in
Introduction to Maintenance Function Maintenance function ensures that all the machines and equipments related to the production and other key functions in the organization are maintained and function properly Maintenance Function plans for the spares and consumables for the maintenance They co-ordinate with outside agencies / other functions in case of layout change / wiring / machine movement, etc Maintenance should ensure that there should not be any breakdowns of any machines Copyright of Hash Management Services LLP www.businessense.in
Responsibilities of an Engineer in the Maintenance Function To bring the machine to the working condition, in case of a break-down Improving the performance of the machines to the specified levels of performance To Move towards Zero Failures , Zero Defects & Zero Accidents Analyzing and stocking the Vital, Essential and Desired spares through VED Analysis Maintaining a MIS report of Break-down register and Preventive Maintenance schedule Coordinating and supporting during layout changes and new machine installations Copyright of Hash Management Services LLP www.businessense.in
Types of Maintenance There are 2 basic types of maintenance Break-down Maintenance Done after the Machine breaks down Preventive Maintenance before the Machine breaks down - done by the Maintenance team at regular intervals to keep the machine in working condition Autonomous Maintenance (AM) is a part of Preventive Maintenance (PM) AM is done by the operator themselves on a daily basis Over a period of time, Break-downs of machines should become zero! Copyright of Hash Management Services LLP www.businessense.in
Break-down Maintenance Once a particular machine breaks down, the operator informs the production supervisor to raise a complaint to the Maintenance team Maintenance team rushes to the machine and fix the issue Most companies have a Service Level Agreement with the Maintenance team to attend the machines ( e.g. maintenance team personnel should reach the machine with in 30 min ) Copyright of Hash Management Services LLP www.businessense.in
Preventive Maintenance This is a schedule based maintenance program which would be done by the maintenance team Daily / weekly / fortnightly / monthly / quarterly plan for all machines A preventive Maintenance calendar should be created covering all major machines in the company and person responsible for the same Copyright of Hash Management Services LLP www.businessense.in
Autonomous Maintenance (AM) Would be done by the operator themselves Cleaning / Lubrication / Re-tightening / Inspection are covered under Autonomous Maintenance Minor spare change can also be covered under AM Copyright of Hash Management Services LLP www.businessense.in
Steps for Implementing AM 1. Preparation 2. Cleaning and Inspection 3. Eliminate Problem Sources and abnormalities 4. Cleaning, Lubrication, Re-tightening, Inspection Checklists and Audits 5. Visual Management Please note that this list covers only the basics. This is not the exhaustive list of steps as prescribed by the TPM model Copyright of Hash Management Services LLP www.businessense.in
Step 1- Preparation Identify the Machine parts and the purpose /activity of the part in the machine Know the function of the machine Know the safety aspect of the machine Operator Training to handle the machine Knowing the machine & its parts is the primary step Copyright of Hash Management Services LLP www.businessense.in
Step 2- Cleaning and Inspection Initial Cleaning of the Machine Identification of Abnormality Hard to Access area Source of Contamination & Localization Unsafe Conditions Copyright of Hash Management Services LLP www.businessense.in
Step 2- Initial Cleaning of the Machine Before cleaning, all WIP materials in the machine to be properly covered. Cleaning Agent should be applied as mentioned in the manual of the machine only Cleaning tools: Cotton Waste Tool Box / Trolley Wire Brushes Ladder , Screw Driver Emery Sheet - Medium Cleaning Agent Kerosene , Soap oil Copyright of Hash Management Services LLP www.businessense.in
Step 2- Identification of Abnormality Abnormalities Where to find them? Dust Non standard Bolts and nuts/ joints Dirt Vibration Lubrication Leak Noise Transmission Rust Misalignment Hydraulics Loose Shaking Pneumatics gas system Damage Deformed Worn out Electrical Missing Safety Copyright of Hash Management Services LLP www.businessense.in
Step 3 Elimination of abnormalities Missing Nut Nut fixed Copyright of Hash Management Services LLP www.businessense.in
Step 3 Elimination of abnormalities Different Nuts Same type nuts Remaining steps with pictures and Report templates are explained in the Certified Manufacturing Professional course. To access login to www.businessense.in Copyright of Hash Management Services LLP www.businessense.in
End of Free Content Please visit our website www.businessense.in to access the full course Certified Manufacturing Professional Our website also contains list of ready-to-use templates and report formats containing Charts and pivot tables. Templates and report formats are available for Purchase, Stores, Production, Quality, Maintenance and HR functions These templates come in excel /word and can be downloaded and used right away At Business Sense, we help clients through consulting engagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools. We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply Chain Re-engineering. You can subscribe to our bi-weekly newsletter here. Follow us: Copyright of Hash Management Services LLP www.businessense.in

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Maintenance english

  • 1. The Essentials - Maintenance HASH MANAGEMENT SERVICES LLP CHENNAI PH: 91766 13965
  • 2. Overview The Essentials series from Business Sense is an initiative to empower the students(freshers) and professionals in performing more efficiently and effectively in the organization This document is a part of the Certified Manufacturing Professional course offered by Business Sense This course is aimed at bridging the gap between the institutions and the industry by providing the fundamentals of manufacturing management which are not offered by any of our institutions/curriculum This course would immensely benefit students and professionals who are joining manufacturing organizations For more details, please visit www.businessense.in At Business Sense, we help clients through consulting engagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools. We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply Chain Re-engineering. You can subscribe to our bi-weekly newsletter here. Follow us: Copyright of Hash Management Services LLP www.businessense.in
  • 3. Contents Section 1 Introduction and Basic Processes Section 2 Autonomous Maintenance Section 3 Pictorial Representations Copyright of Hash Management Services LLP www.businessense.in
  • 4. Introduction to Maintenance Function Maintenance function ensures that all the machines and equipments related to the production and other key functions in the organization are maintained and function properly Maintenance Function plans for the spares and consumables for the maintenance They co-ordinate with outside agencies / other functions in case of layout change / wiring / machine movement, etc Maintenance should ensure that there should not be any breakdowns of any machines Copyright of Hash Management Services LLP www.businessense.in
  • 5. Responsibilities of an Engineer in the Maintenance Function To bring the machine to the working condition, in case of a break-down Improving the performance of the machines to the specified levels of performance To Move towards Zero Failures , Zero Defects & Zero Accidents Analyzing and stocking the Vital, Essential and Desired spares through VED Analysis Maintaining a MIS report of Break-down register and Preventive Maintenance schedule Coordinating and supporting during layout changes and new machine installations Copyright of Hash Management Services LLP www.businessense.in
  • 6. Types of Maintenance There are 2 basic types of maintenance Break-down Maintenance Done after the Machine breaks down Preventive Maintenance before the Machine breaks down - done by the Maintenance team at regular intervals to keep the machine in working condition Autonomous Maintenance (AM) is a part of Preventive Maintenance (PM) AM is done by the operator themselves on a daily basis Over a period of time, Break-downs of machines should become zero! Copyright of Hash Management Services LLP www.businessense.in
  • 7. Break-down Maintenance Once a particular machine breaks down, the operator informs the production supervisor to raise a complaint to the Maintenance team Maintenance team rushes to the machine and fix the issue Most companies have a Service Level Agreement with the Maintenance team to attend the machines ( e.g. maintenance team personnel should reach the machine with in 30 min ) Copyright of Hash Management Services LLP www.businessense.in
  • 8. Preventive Maintenance This is a schedule based maintenance program which would be done by the maintenance team Daily / weekly / fortnightly / monthly / quarterly plan for all machines A preventive Maintenance calendar should be created covering all major machines in the company and person responsible for the same Copyright of Hash Management Services LLP www.businessense.in
  • 9. Autonomous Maintenance (AM) Would be done by the operator themselves Cleaning / Lubrication / Re-tightening / Inspection are covered under Autonomous Maintenance Minor spare change can also be covered under AM Copyright of Hash Management Services LLP www.businessense.in
  • 10. Steps for Implementing AM 1. Preparation 2. Cleaning and Inspection 3. Eliminate Problem Sources and abnormalities 4. Cleaning, Lubrication, Re-tightening, Inspection Checklists and Audits 5. Visual Management Please note that this list covers only the basics. This is not the exhaustive list of steps as prescribed by the TPM model Copyright of Hash Management Services LLP www.businessense.in
  • 11. Step 1- Preparation Identify the Machine parts and the purpose /activity of the part in the machine Know the function of the machine Know the safety aspect of the machine Operator Training to handle the machine Knowing the machine & its parts is the primary step Copyright of Hash Management Services LLP www.businessense.in
  • 12. Step 2- Cleaning and Inspection Initial Cleaning of the Machine Identification of Abnormality Hard to Access area Source of Contamination & Localization Unsafe Conditions Copyright of Hash Management Services LLP www.businessense.in
  • 13. Step 2- Initial Cleaning of the Machine Before cleaning, all WIP materials in the machine to be properly covered. Cleaning Agent should be applied as mentioned in the manual of the machine only Cleaning tools: Cotton Waste Tool Box / Trolley Wire Brushes Ladder , Screw Driver Emery Sheet - Medium Cleaning Agent Kerosene , Soap oil Copyright of Hash Management Services LLP www.businessense.in
  • 14. Step 2- Identification of Abnormality Abnormalities Where to find them? Dust Non standard Bolts and nuts/ joints Dirt Vibration Lubrication Leak Noise Transmission Rust Misalignment Hydraulics Loose Shaking Pneumatics gas system Damage Deformed Worn out Electrical Missing Safety Copyright of Hash Management Services LLP www.businessense.in
  • 15. Step 3 Elimination of abnormalities Missing Nut Nut fixed Copyright of Hash Management Services LLP www.businessense.in
  • 16. Step 3 Elimination of abnormalities Different Nuts Same type nuts Remaining steps with pictures and Report templates are explained in the Certified Manufacturing Professional course. To access login to www.businessense.in Copyright of Hash Management Services LLP www.businessense.in
  • 17. End of Free Content Please visit our website www.businessense.in to access the full course Certified Manufacturing Professional Our website also contains list of ready-to-use templates and report formats containing Charts and pivot tables. Templates and report formats are available for Purchase, Stores, Production, Quality, Maintenance and HR functions These templates come in excel /word and can be downloaded and used right away At Business Sense, we help clients through consulting engagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools. We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply Chain Re-engineering. You can subscribe to our bi-weekly newsletter here. Follow us: Copyright of Hash Management Services LLP www.businessense.in