Using fundamentals to break the breakdown maintenance cycle. How to get zero breakdown maintenance strategy ppt. The same concept applies to maintaining production systems. If youre ready to do it yourself, watch these videos for stepbystep instructions to maintain your riding lawn mower. Dec 20, 2016 there are two main points to be made about breakdown maintenance 1. Model numbers can be found on the product identification tag located on your snapper product. Productivity needs for nextgeneration maintenance springerlink. College abstract the complex nature of modern equipment and systems often lead to failures and as a. Maintenancezero breakdown troubleshooting machines scribd. Zero breakdown activities the biggest challenge during the tpm implementation is to change the tradesmen mind set from the reactive approach firemen to a proactive approach machine physician.
But, in many peoples mind, breakdown maintenance is urgent maintenance, maintenance that needs to be done right now i. Placing heavier and larger objects on a lighter duty conveyor system will add stress and wear to not only. Corrective maintenance is unplanned when a preventive maintenance schedule is in place, but a breakdown occurs between scheduled maintenance actions. Observing the state of the system is known as condition monitoring. Maintenancezero breakdown free download as pdf file. Product specifications and manuals downloads subzero. Tpm planned maintenance 4 phases to zero unplanned breakdown rsa reliability and maintenance consultancy firm presents proposed contents for inhouse training. Worlds best powerpoint templates crystalgraphics offers more powerpoint templates than anyone else in the world, with over 4 million to choose from. This computerassisted maintenance software has all the usual features of cmms. Winner of the standing ovation award for best powerpoint templates from presentations magazine. Apply to maintenance technician, maintenance person, senior electrician and more. It is important not to perform excessive maintenance activities 4. Jul 20, 20 first of all, we should accept that zero breakdown can be achieved. On the other hand, if there is no breakdown before l, then a pm cost will be incurred at time l.
Various classifications for maintenance are provided in the literature. Intelligent maintenance california state university, northridge. The better the condition of the parts, the better and longer the equipment will run. Keep your john deere riding lawn mower running its best and know how you mow with the john deere mowerplus app. Sap pm breakdown maintenance sap pm tutorials youtube. Chapter 5 types of maintenance programs us department of energy.
Using fundamentals to break the breakdown maintenance cycle a saffal introducnon during 1991 1993 the author interviewed approximately thirty senior managers of varying responsibilities in either the engineering, construction or operation of a heavy industrial facility. The second premise is that people use plant and equipment. A manufacturing date cod eis stamped on zero max dri ve andgearhead cases above the label. Reliability and maintenance consultancy firm presents tpm. By balancing portfolio maturity with operational agility, it. Zero breakdowns step 1 maintaining basic conditions. In this blog, we will discuss deterioration prevention which focuses on the equipment related maintenance issues. Breakdown and reliability analysis in a process industry. There are many different ways to approach the maintenance of facilities and equipment. Pdf maintenance strategies and their combine impact on. Zero breakdown strategies are designed to provide cost effective solutions to equipment problems that will allow companies to realize the maximum return on investment in their assets. One of the total productive maintenance goals for production line development is the zero breakdown. Maintenance for zero breakdowns requires total involvement, greater commitment and continuous effort by plant people. Major maintenance typesor tactics adapted from bs 306 11 various maintenance approaches such as rcm and bcm employ most or all of the maintenance types or tactics in figure 2.
Figure 2 shows the classification of the british standard, bs en 306 11. Autonomous maintenance step 2 continuously improving. Zero breakdown maintenance is all about working for the ultimate goal with a winning maintenance strategy. Cbm is based on using realtime data to prioritize and optimize maintenance resources.
These videos are intended as a general guide for maintenance tasks. The standardisation roadmap of predictive maintenance for. Breakdown maintenance procedure of the equipments and. Pdf maintenance and its types engr sajid chaudhary. Maintenance instructions kohler tipslubrication use only kohler oil filters. Apr 11, 2020 a policy of breakdown maintenance is sometimes instituted when a facility or business has scheduled to close or cease operations, especially if there are no plans to continue using the equipment afterward. Breakdown maintenance mechatronic solution partner. How to achieve zero breakdowns in the tequila production process. View and download walker t25i operators manual online. Pdf maintenance strategies to reduce downtime due to. If the wall thickness has reduced by 25%, the valve must be replaced. An analysis of maintenance strategies and development of a model. Conditionbased maintenance was introduced to try to maintain the correct equipment at the right time.
The service manual is a service guide for use by service technicians. The overall maintenance plan will be based on the standards put in place. The app helps you determine the best time to mow, communicates expert premow tips, offers maintenance reminders, and provides walkthrough guides, and more. However, both departments can achieve significant results by combining both autonomous and planned maintenance, when implemented. Corrective maintenance activities are generated from preventive. Audits are a stepwise process with a progression of awards levels 5 in. Factory cmms is the new cmms software developed and developed by factory systems. Pdf format is a breakdown maintenance plan even possible. This includes the most basic practices of proper lubrication, cleaning and assembly. The definition of breakdown maintenance is quite simple, being, let the machine run its course to the point of not being able to function properly and then fix it. Maintenance 4 phases to zero unplanned breakdown strategy.
With predictive devices currently available, it is incumbent upon. Allows maintenance service department to analyze the maintenance requirements of each machineequipment in advance so that a plan for the spares or resources can be prepared. Learn about the ongoing maintenance you should do to keep things running smoothly. However, there are some things that you can do to make your maintenance 7 breakdown maintenance planning tips with. The first is that equipment will only work properly if its parts work properly. The fundamental premise behind this book is that many equipment failures are actually caused by maintenance practices particularly the failure to establish andor follow appropriate quality standards for the performance of maintenance work. Finally, we wish to gratefully acknowledge financial support from the world health organization and contributors to its special programs, namely the danish international development agency dandida and the u. Vision the vision for the center for intelligent maintenance systems is to enable products and systems to achieve and sustain near zero breakdown performance, and ultimately transform the traditional maintenance practices from fail and fix to predict and prevent methodology. The first step is to explain that a repair does not finish when they fix the machine, but it finishes when they take action to prevent the recurrence. Our new pdfcreator online lets you merge pdf files, convert office files to pdf, and images to pdf in your browser. Headconcerned department area incharge shall be responsible for intimating the engineering department on the breakdown of the equipmentsmachines, through maintenance work order as per this sop.
Compared with traditional breakdown maintenance and periodic maintenance technology, the predictive maintenance technique, which takes the feature recognition, life prediction, fault analysis, maintenance planning as the core technologies, is characte. The concerned technician shall follow the breakdown maintenance procedure as per this sop. Unscheduled stop of the equipment, performing loss of function, for over 10. In the case of breakdown maintenance youve had a failure and so now it needs to be fixed. Corrective maintenance is performed when a breakdown occurs between scheduled preventive maintenance occurrences. The 7 steps concept of autonomous maintenance operators are similar to 7 steps of planned effective maintenance trades. If a change has been made to your machine which is not reflected in this parts manual, see your authorized dealer for current information and parts. Breakdown maintenance powerpoint template sketchbubble. Sop for breakdown maintenance of equipment, machinery and. Freebie key maintenance metrics useful maintenance metrics for your maintenance program.
Always look to reduce time for a planned maintenance activity, identify items that can be checked inprocess. Past and current maintenance practices in both the private and government sectors would imply that maintenance is the actions associated with equipment repair after it is broken. Top 10 preventative maintenance tips for product handling. After reading this article you will learn about corrective maintenance in industries. Predictive maintenance or prognostics is critical to any engineering systems to avoid system breakdown, in particular, for complex systems. Maintenance management approaches have been studied. Breakdown maintenance is maintenance performed on equipment that has broken down and is unusable. Manufacturing plants are exposed to newer and rapidly changing paradigms. It is different from preventive maintenance as preventive maintenance is performed in order to keep a machine running while breakdown maintenance is done to fix a machine that is completely not working.
I built an ms access database which uses the datediff function in a query, to calculate the time lapsed between the production date and time requested and the work completed date and time this function is also used for the maintenance. Check the results of planned maintenance and if items are continuously ok or always need replacing, adjust frequency. Maintenance strategies to reduce downtime due to machine. Product specifications and manuals use this page to access design specifications, use and care manuals, cad files, downloads, installation guides and other documentation about current and past subzero, wolf, and cove product models. Achieve zero defects, zero breakdown and zero accidents in all functional areas of the organization. Opposed to preventive maintenance in which a maintenance schedule is assigned to a machine before a breakdown ever occurs, preventing future delays in production. Zero breakdown strategies step 3 deterioration prevention. There is now a greater awareness of the potential of maintenance management functions and what it can contribute with utmost productivity and effectiveness in realizing economic goals of a company. This blog starts the first of five steps to achieving zero breakdowns.
Zero breakdown strategies step 3 deterioration prevention in our last blog, we discussed operating standards which focused more on issues related to the operation of the equipment. Creates report of all the preventive and breakdown maintenance jobs done in the past. Our breakdown maintenance powerpoint template helps an organization focus on optimizing preventive maintenance programs for critical equipment. As reported by mather, there still remain many opportunities to bridge the gap between the philosophy and practical application of these strategies 6. Maintenance plan breakdown fall maintenace plan spring maintenance plan check system operation replace or clean filters check pilot for proper functions check valve assembly checkadjust burner check for gas leaks lubricate all moving parts inspect thermostat operation check blower assembly. An introduction to total productive maintenance tpm by venkatesh j. This means that unnecessary maintenance will be performed. For equipment to be fully utilized, a blend of all three parameters determines its actual. The oil level should be within may not seal properly andor have the incorrect. Conditionbased maintenance is the third method used to drive the creation of preventive maintenance work. The standardisation roadmap of predictive maintenance for sino. Maintenance can be may be performed immediately or at a later date, depending on the availability of tools, parts, and personnel. Since 1971 auditing and presenting awards for tpm achievement since 1991 internationally. Reactive maintenance is performed if a breakdown occurs because a maintenance strategy has not yet been put in place.
Your zero breakdown maintenance strategy starts with bringing worldclass reliability and maintenance training, education and knowledge to your people discover and use the most ideal maintenance strategies and best maintenance practices in your operation for zero equipment failures. Review of maintenance standards time based maintenance of electrical and. Through the utilization of various nondestructive testing and measuring techniques, predictive maintenance determines equipment status before a breakdown occurs. Toward zero breakdown istanbul 12 december 2014 16 assess equipment and understand current status assess the planned maintenance system build up a predictive maintenance system build up a periodical maintenance system build up an information management system restore deteriorated conditions and improve weakness 1 2 4 3 5 6. The age and condition of equipment, the degree of technology involved, the type of. Zero breakdown maintenance is built on three key premises. Phase 1 deals with stabilizing mtbf, main activity involved here is restoration by establishing equipment. That means you can automate everyday business tasks, get uptodate financials and run your business from wherever you are. How to get zero breakdown maintenance strategy ppt powerpoint. Zero maintenance cache protection despite their obvious value, bbus are not the optimal solution from a capital expense capex or an operating expense opex standpoint. In my last blog, i raised the question about zero breakdowns and if it was possible to achieve that state of equipment reliability. It is also referred to as maintenance or engineering work related to unforseen plant breakdowns. And depending on the risk associated with that breakdown it could be urgent or less urgent.
Check breakdown frequency between planned maintenance and adjust schedule andor content accordingly. Theyll give your presentations a professional, memorable appearance the kind of sophisticated look that todays audiences expect. Always give the date code when requesting service or ordering parts. This roadmap focuses on the predictive maintenance in the intelligent. Preventive maintenance and predictive maintenance schedules. Top 10 preventative maintenance tips for product handling conveyors 10. Sop for breakdown maintenance of equipment, machinery and facility standard operating procedure of break down maintenance of equipment in different pharmaceutical departments and record information in machine history card. It provides the necessary information needed to perform normal maintenance requirements on these units. Zero breakdown activities total productive maintenance. They are used to look up your products operators manual and illustrated parts lists. In reality, whether a function loss or a function reduction breakdowns, all breakdowns impact a company financially. View vital information in this zero breakdown maintenance training course powerpoint ppt. Maintenance strategies to reduce downtime due to machine positional errors conference paper pdf available september 2014 with 5,544 reads how we measure reads.
Zero product defects, zero breakdowns and zero accidents. Our zero turn and standon mowers are backed with nothing but the best. Approaching zero breakdowns by advancing breakdown analysis. Xeros online accounting software lives in the cloud. Corrective repair time distribution with pdf g1l1 dg1l1dl1. Action plans in implementation of total productive maintenance. Sep 10, 2018 zero breakdown activities the biggest challenge during the tpm implementation is to change the tradesmen mind set from the reactive approach firemen to a proactive approach machine physician.
The concern is about formulating the facilitys optimal maintenance schedule. The general goal is to combine fault masking and active. Avoid misuse of conveyors the misuse of a conveyor is a common cause of reducing the life of a conveyor system. Given preventive maintenance pm interval l, if a breakdown occurs before l, then a breakdown maintenance cost will be incurred, and the machine will be repaired and the next time between breakdowns tbb will start. Tpm reference standard jipm japan institute of plant maintenance comes from the best of japanese industrial excellence and evolved from the heat of the continuing energy crisis and globalization challenges to achieve more with less. Maintenance the valve should be at zero pressure and ambient temperature prior to any. This book is an interesting contribution to the maintenance field, and would be of interest both to those who are embarking on a total productive maintenance tpm program within their organization, as well those who are looking to move beyond failure prevention and prediction, and towards failure elimination. The first le tt er indicates the year k being 1970, the second letter indicates the month a is january. Zero breakdowns step 1 maintaining basic conditions in my last blog, i raised the question about zero breakdowns and if it was possible to achieve that state of equipment reliability.
Pdf this chapter looks at the concept of zeromaintenance, in particular how it relates to design. Maintenance, either planned or unplanned is a service. One is the heavy level of operator involvement in order to fulfill the requirements of operator which is becoming increasingly involved in breakdown maintenance, these must be. Maintenance and operation manual ulfm post indicator valve configuration. Action plans for implementation of total productive maintenance shamsuddin ahmed and masjuki hj hassan faculty of engineering, university of malaya, malaysia abstract maintenance is an inevitable function in manufacturing plants. Zero breakdown concepts reliability engineering engineering. Requests for maintenance are generated from condition readings entered into sap.
Breakdown and reliability analysis in a process industry dibyojyoti deka1,dr. It means that people waits until equipment fails and repair it. Maintenance and operation manual united water products. Such a system will determine the equipments health, and act only when maintenance is. Ppt total productive maintenance powerpoint presentation. Maintenance strategies and their combine impact on manufacturing performance 15. Strategy which helps in zero break down of an equipment is as follows as per my experience1. Repairs or replacements performed after a machine has failed to return to its functional state following a malfunction or shutdown.
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