Plant Maintenance

Introduction Impacts of Poor Maintenance Maintenance Process Types of Maintenance Total Productive Maintenance(TPM) Preventive Maintenance to TPM Five Pillars of TPM TPM vs. TQM

What Is Plant Maintenance?

Plant maintenance-methods, strategies, and practices used to keep an industrial factory running efficiently. include anything from regular checks of equipment to make sure they are functioning properly, to cleaning garbage bins and toilets. The general aim of plant maintenance is to create a productive working environment that is also safe for workers. A maintenance plan can include scheduling times for equipment checkups, trouble-shooting, and general clean-up. each place of business generally has its own maintenance plan, tailored to its particularities.

IMPACT OF POOR MAINTENANCE

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Reduction of Production capacity Increase of production cost Poor product and service quality

Threat to employee and consumer safety

Affects customer satisfaction

Maintenance Process

Description of the object conditionThe most important element in this area is the maintenance notification. This is used to describe the condition of the technical object or to report a malfunction at a technical object and request the damage is repaired. Execution of maintenance tasksThe most important element in this area is the maintenance order. This is used to plan the execution of maintenance activities in detail, monitor the progress of work and settle the costs of maintenance tasks. Completion of maintenance tasksThe most important element in this area is the maintenance history. This is used for long-term saving of the most important maintenance data. This data can be called up for evaluation at any time.

Types Of Maintenance

1. Breakdown maintenance : people waits until equipment fails and repair it. Such a thing could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost.

2. Preventive maintenance ( 1951 ): daily maintenance ( cleaning, inspection, oiling and re-tightening ). prevent failure through the periodic inspection or equipment condition diagnosis

3. Corrective maintenance ( 1957 ) : It improves equipment and its components so that preventive maintenance can be carried out reliably.

Equipment with design weakness must be redesigned to improve reliability or improving maintainability

4. Maintenance prevention ( 1960 ): It indicates the design of a new equipment. Weakness of current machines are sufficiently studied and are incorporated

Challenging limits: PM to TPM

Total Productive Maintenance

Productive + Employee Participation

Preventive +Maintenance Prevention

Modification for improving reliability

Preventive + Automation Maintenance

However with the automation of Nippondenso, they introduced

Preventive Maintenance

Nippondenso of the Toyota group introduced in Japan in 1960

Total Productive Maintenance

Maintenance program which involves a newly defined concept for maintaining plants and equipment. (Medical Science of machines) TPM no longer regarded as non-profit activity. Integral part of the manufacturing process. Objectives Avoid wastage in a quickly changing economic environment. Producing goods without reducing product quality. Reduce cost. Goods send to the customers must be non defective.

Five Pillars of TPM

Comparison of TPM & TQM

Category
Object Mains of Attaining goals Target

TPM
Equipment ( Input and cause ) Employees participation and it is hardware oriented Elimination of losses and wastes.

TQM
Quality ( Output and effects ) Systematize the management. It is software oriented Quality for PPM

Presented By:

Nikhil Kulkarni MMS-A Roll No-34