The Essentials - Maintenance

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Overview

The Essentials series from Business Sense is an initiative to empower the professionals and students in performing more efficiently and effectively in the organization This publication 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 professionals and students who are joining manufacturing organizations At Business Sense, we help medium scale manufacturing units improve their operational efficiency through consulting engagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools We promise to double the productivity in less than 33 days of our effort In addition, our web application would help the senior management in monitoring the important business updates every day and provide them analytics and enable them better decision making. Useful if your organization do not have an ERP

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Contents
Section 1 Introduction and Basic Processes Section 2 Autonomous Maintenance Section 3 Pictorial Representations

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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

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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
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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!

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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 )

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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

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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

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Steps for Implementing AM

1. 2. 3.

Preparation Cleaning and Inspection Eliminate Problem Sources and abnormalities

4.
5.

Cleaning, Lubrication, Re-tightening, Inspection Checklists and Audits

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
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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

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Step 2- Cleaning and Inspection

Initial Cleaning of the Machine

Identification of

Abnormality

Hard to Access area

Source of Contamination & Localization Unsafe Conditions

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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

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Step 2- Identification of Abnormality

Abnormalities

Where to find them?

Dust Dirt Leak Rust Loose Damage Deformed

Non standard Vibration Noise Misalignment Shaking Worn out Missing

Bolts and nuts/ joints Lubrication Transmission Hydraulics Pneumatics gas system Electrical Safety

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Step 3 Elimination of abnormalities

Missing Nut

Nut fixed

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Step 3 Elimination of abnormalities

Different Nuts
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Same type nuts

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End of Free Content

Please visit our website www.businessense.in to access the full content through an interactive ELearning course Our website also contains list of ready-to-use templates and report formats with 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 medium scale manufacturing units improve their operational efficiency Our app would help them in monitoring the important business updates every day and provide them analytics and enable them better decision making We also work with our clients on consulting engagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools We promise to double the productivity in less than 33 days of our effort

You can subscribe to our bi-weekly newsletter here. Follow us:

www.businessense.in

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