automotive industry cluster east cape cleaner production
TRANSCRIPT
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Automotive Industry Cluster
East Cape
CLEANER PRODUCTION
CLUSTER
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PLANNED MAINTENANCE TARGET
ZERO EQUIPMENT FAILUE
AND BREAKDO
WN
REDUCE MAINTENANCE COST
BY 20%
ENSURE AVAILABILI
TY OF SPARES ALL THE
TIME
IMPROVE RELIABILIT
Y AND MAINTAINABILITY BY
50%
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Deterioration
Time
Performance
Natural Deterioration
Forced Deterioration
Limit Line
What would cause forced deterioration ?
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Forced Deterioration
• Sources – Vibration – Wear – Dirt – Dust – Debris
•Countermeasures Tightening Lubrication Cleaning
Aim of Autonomous Maintenance is to move the forced deterioration line closer to the natural deterioration line.
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Combination Of Breakdown Causes •Five requirements for zero breakdowns:
1. Maintain basic conditions
2. Maintain operating conditions
3. Restore deterioration 4. Correct design
weaknesses 5. Improve operating &
maintenance skills
Basic conditions neglected
Inadequate skills
Inherent design weakness
Deterioration unchecked
Operating standards not followed
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7 Steps for PM
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Types of Maintenance
• Breakdown Maintenance - Intentional, not unplanned
• Periodic Maintenance - Time-based or Inspection & Repair
• Predictive Maintenance - CBM, use of technology for assessing condition
• Corrective Maintenance - Recurrence prevention
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Responsibility for Maintenance
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Pilot Area
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Negative Map
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Planned Maintenance Implementation Plan
1 – Initial Cleaning 2 – Sources of contamination, Hard-to-reach area 3 – Standardize
4 –Inspection system 5 – Entire process inspection
6 – A.M. System 7 – A.M. Management
INCREASE TIMELIFE Improve MTBF SYSTEMATIC REPAIR FAILURE PREDICTION
PHASE 1 PHASE 2 PHASE 3 PHASE 4
1 –Equipement Audit (Current)
2 –Repair degradations and improve weakness
3 – Information system (Database)
4 – Preventive Maintenance System 5 -Predictive
Maintenance System
AU
TON
OM
OU
S
MA
INTE
NA
NC
E
MA
INTE
NA
NC
E
6 -Evaluate &
Establish P
LAN
NE
D M
AIN
TEN
AN
CE
S
YSTE
M
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Benefits of PM
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Implementation of Planned Maintenance
EVALUATE THE PLANNED MAINTENANCE SYSTEM
BUILD A PREDICTIVE MANITENANCE SYSTEM
BUILD A PERIODIC MANAGEMENT SYSTEM
BUILD AN INFORMATION MANAGEMENT SYSTEM
RESTORE DETERIORATION AND CORRECT WEAKNESS
EVALUATION OF EQUIPMENT FAILURE/BREAKDOWN STATUS AND UNDERSTAND SITUATION
SUPPORT AND GUIDANCE OF JISHU HOZEN ACTIVITY
STEP 7
STEP 6
STEP 5
STEP 4
STEP 3
STEP 2
STEP 1
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Guidance and Support for Autonomous Maintenance
GUIDANCE AND SUPPORTFOR AUTONOMOUS
MAINTENANCE
Support for RedTag system
Red Tagremoval listand removal
plan
Countermeasuresfor generation
sources
Support foreliminating the 4evils (Dirt, Rust,
Heat and Vibration)
Maintaining visualcontrol and displayinglabels, types of oil etc.
Support for makingstandards of cleaning,
lubrication andinspecting. Education ofoverall and inspection
for leader.
Training to ImproveMaintenance related
technical ability
STEP 1
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Step 2
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Evaluate and Understand the Current Conditions Evaluate and Understand the
Current Conditions
Creation andmaintenance of
equipment ledger
Creation andimplementation of
equipment evaluationstandard and ranking
EquipmentMaintenance
Record
Select PMequipment
MTBF
Check sheetof equipment
currentstatus
Frequency& Intensity
Rate
Process CapabilitySheet
MTTR MaintenanceCost
Set goals for theteam with planned
maintenance
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Example Criteria for Evaluating Equipment
To decide which equipment receives planned maintenance
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Equipment Ledger Control
(Page 30 PM)
• Equipment logs are raw data for evaluating equipment. Must have design data and show equipment’s operating and maintenance history.
• Collect all data on the
failures/breakdowns, which caused production loss and analyse
Equipment Management RecordAsset No.
Equipment name
Model
Designed by
Date created
Purchased from
Insta
llation location
Purchased date
Purchase price per (R1,000)
Drawing
Substation/line nameDate
Periodic maintenance/modifications and improvements
Amount per (R1, 000)
Main failure and repair Amount per (R1, 000)
Date Location Details (in-house manhour)Date Location Details (in-house manhour)
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Parts History of Equipment
(Page 31 PM)
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Parts Breakdown History Record
(Page 32 PM)
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Equipment Clarity Classification
• Evaluate each piece of equipment in terms of its effect on safety, quality, operability, maintainability, etc. • Rank equipment (as A, B, or C, for example) and perform maintenance on all units ranked A or B, as well as those for which zero failure is a legal requirement.
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Critical Ranking and Maintenance Method
(Page 33 PM) • Rank failures as major, intermediate, or minor depending on their effect on equipment.
Evaluation Chart for Ranking Equipment (Evaluation Table for Selecting Priority Equipment)
4 2
4 2 1
4 2 1
1
4 2 1
4 2 1
Safety (SM)
9 Risk of a failure causing injury
10 Risk of a failure causing pollution
5
5
5
Quality (Q)
7
8Cost (C)
Product fabrication process capability
Fabrication cost
Total repair cost
6
1
Frequency of failures 4 2 1
1Production
(PD)
Average level of operation 5 4 2
Impact of a failure on other equipment 5 4 2
2
3
4
5 Downtime for repairing failures 4 2
1 1
Availability of space machine or alternate machine, and the ease of switchover 4 2 1
Classification EvaluationEvaluation points
Equipment name
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Breakdown Occurrence List
• Obtain data on failure numbers, frequencies and severities, MTBFs ,etc.
• MTTRs (mean time to repair), maintenance costs, etc.
Control No. Name
1 2 3 4 5 6 7 8 9 10 11 12
Machine Failure Frequency Check-up Table
Month
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Activity Plan to Eliminate Breakdowns
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Set goals for reducing these through planned maintenance
Examples of planned maintenance goals
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THANK YOU