Maximo Reporting

1. Breakdown maintenance:
In this type of maintenance, no care is taken for the machine, until equipment fails. Repair is then undertaken. This type of maintenance could be used when the equipment failure does not significantly affect the operation or production or generate any significant loss other than repair cost. However, an important aspect is that the failure of a component from a big machine may be injurious to the operator. Hence breakdown maintenance should be avoided.

2. Preventive maintenance:
It is a daily maintenance (cleaning, inspection, oiling and re-tightening), design to retain the healthy condition of equipment and prevent failure through the prevention of deterioration, periodic inspection or equipment condition diagnosis, to measure deterioration. It is further divided into periodic maintenance and predictive maintenance. Just like human life is extended by preventive medicine, the equipment service life can be prolonged by doing preventive maintenance.
2a. Periodic maintenance (Time based maintenance - TBM):
Time based maintenance consists of periodically inspecting, servicing and
cleaning equipment and replacing parts to prevent sudden failure and process
problems. E.g. Replacement of coolant or oil every 15 days.
2b. Predictive maintenance:
This is a method in which the service life of important part is predicted based
on inspection or diagnosis, in order to use the parts to the limit of their
service life. Compared to periodic maintenance, predictive maintenance is
condition-based maintenance. It manages trend values, by measuring and analyzing
data about deterioration and employs a surveillance system, designed to monitor
conditions through an on-line system. E.g. Replacement of coolant or oil, if
there is a change in color. Change in color indicates the deteriorating
condition of the oil. As this is a condition-based maintenance, the oil or
coolant is replaced.

3. Corrective maintenance:
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. This happens at the equipment user level. E.g. installing a guard, to prevent the burrs falling in the coolant tank.

4. Maintenance prevention:
This program indicates the design of new equipment. Weakness of current machines is sufficiently studied (on site information leading to failure prevention, easier maintenance and prevents of defects, safety and ease of manufacturing). The observations and the study made are shared with the equipment manufacturer and necessary changes are made in the design of new machine.

In today’s industrial scenario huge losses/wastage occur in the manufacturing shop floor. This waste is due to operators, maintenance personal, process, tooling problems and non-availability of components in time etc. Other forms of waste includes idle machines, idle manpower, break down machine, rejected parts etc are all examples of waste. The quality related waste are of significant importance as they matter the company in terms of time, material and the hard earned reputation of the company. There are also other invisible wastes like operating the machines below the rated speed, start up loss, break down of the machines and bottle necks in process. Zero oriented concepts such as zero tolerance for waste, defects, break down and zero accidents are becoming a pre-requisite in the manufacturing and assembly industry. In this situation, a revolutionary concept of TPM has been adopted in many industries across the world to address the above said problems.

What is Total Productive Maintenance (TPM)?
It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.
TPM brings maintenance into focus as a necessary and vitally important part of the business. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.

Why TPM?

TPM was introduced to achieve the following objectives. The important ones are listed below.
• Avoid wastage in a quickly changing economic environment.
• Producing goods without reducing product quality.
• Reduce cost.
• Produce a low batch quantity at the earliest possible time.
• Goods send to the customers must be non-defective.

Similarities and differences between TQM and TPM:

The TPM program closely resembles the popular Total Quality Management (TQM) program. Many of the tools such as employee empowerment, benchmarking, documentation, etc. used in TQM are used to implement and optimize TPM. Following are the similarities between the two.

1. Total commitment to the program by upper level management is required in both
programmes
J. Venkatesh Monday, April 16, 2007 1
2. Employees must be empowered to initiate corrective action, and
3. A long-range outlook must be accepted as TPM may take a year or more to
implement and is an on-going process. Changes in employee mind-set toward their
job responsibilities must take place as well.

Identification of the underlying problem

Whenever a component or product fails in service or if failure occurs in manufacturing or during production processing, failure analysis plays a very important role. In any case, one must determine the cause of failure to prevent future occurrence, and/or to improve the performance of the device, component or structure.

Typical examples of systems/equipment that can be analyzed are electrical generators, heat exchangers, valves, control systems, pumps, components of gas turbines and compressors.

Failure Analysis will disclose;
• Why the event, failure or breakdown occurred
• How future failures can be controlled or eliminated

Analysis to Identify the Causes of Failure / Breakdown

Failure analyses of the repairable systems focus on the model capability to identify, control and eliminate future failures, for a system.
• Root Cause Analysis
• Pareto Analysis for Downtime
• MTBF-MTTR Trending for Bad Assets
• Effect of MTTR on Asset Availability
• Breakdown Analysis
• Identification of Dominant Failure Codes
• Effect of Unplanned Cost on Maintenance Cost
• Analyze Reactive Maintenance
Benefits
• Uses advanced investigative techniques
• Identifies early (unlikely) life failures
• Extends equipment lifetime
• Reduced cost of maintenance
• Improves availability “up-time” and increased production
• Increases safety
• Easy to identify for potential losses where risk is included