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CHAIN
DEPARMENT
BREAKDOWN REDUCTION
Basic considerations
by simple causes
Example
Company EFES, Plant Karaganda - Breakdowns
reduction group
Breakdo
wn:
Failed:
extruder
stop
electrical
motor
Sequence of
events:
Seal on
motor
broken
Entry of
grease and
carbon
powder
Breakdown
of
insulation
"Hidden"
anomaly
Earth fault
Motor
failed
Breakdo
wn
Cause
analysis
Example (cont'd)
Actions resulting from analysis
Modification of cleaning and
being neglected
Breakdowns
Hidden
anomalies
Dust, soiling, adhesion of raw
materials
Abrasion, looseness, leaks
Corrosion, deformation, cracks
Temperature, vibration,
sound and other errors
No
bolt!
Is there
the name
plate?
Are the
limits of
voltage and
current
shown?
Mess
y
wirin
g!
30
Are
four
bolts used
to fix the
dog?
The door
will not
close
55
Tightening of
the lock
nut!
Is the oil
temperat
ure OK?
Methods to avoid
loosening
Oil
leakage!!
Oil
leaka
ge!
Loosen
ed
It's hard to
check oil
quantity and oil
pressure!
After
Accelerated deterioration
Defect
Infiltration of foreign bodies in
Speed loss
Insufficient cleaning increases
Breakdowns
The infiltration of foreign bodies in rotating parts, in sliding parts, in
pneumatic and hydraulic systems, in electric and control systems, in
sensors, etc. generates malfunctions and breakdowns , blockage,
resistance and feeding of inadequate power
Fundamental Rule
It is normal for a
machine to
break down!
Toda
y
Tomorro
w
Design weakness
Lack of preventive
maintenance
Previous quick fix
Incorrect production
operation
Spare part quality
Lack of spare parts
a. 1% --> 0%
b.Zero breakdowns
c.Only preventive maintenance
d. Condition-based maintenance
e.Auton. Mngt. activities stable
and refined
a. 5% --> 1%
f. Life span predicted
b. Chronic and some sporadic breakdowns
c. Mostly preventive maintenance
d.Time-based maintenance
e.Autonomous Management activities well
established
f. Life span stable and being lenghtened
a. 10% --> 5%
b. Sporadic and chronic breakdowns
c. Some preventive maintenance
activities
d. Some daily maintenance
activities
a. ---> 10%
e.Autonomous Management being
b.Repetitive
organized
c.Breakdown maintenance
f. Lifealmost
span measured but unstable
exclusive
d. None (only breakdown maintenance)
e.No Autonomous Management
activities
f. Parts life span, although measured,
but unstable
Applied
preventive
maintenance
techniques
Breakdowns
types
Breakdown
losses
1
2
3
Autonomo
us
Managem
ent
Parts
life
Impact of
breakdo
wn (*)
Reduce machine
Waste
material, energy equipment and
availability
(Productivi
ty)
Q
(Qualit
y)
C
(Costs
)
D
(Deliver
y)
S
(Safet
y)
M
(Personn
el
Motivatio
n)
Description of
impact
manpower time
Create
defects
work
Require inventory
downstream
Create delays in
production plans
Create high-risk
situations
Create
dissatisfaction
(*
)
=
High
=
Medium
=
Low
Define preventive
preventive
Define
maintenance
maintenance
plans
plans
Highlight the
the
Highlight
causes of
of
causes
sporadic
sporadic
breakdowns
breakdowns
Attack repetitive
Attack
repetitive
breakdowns
breakdowns
Restore basic
basic
Restore
condition in
in critical
critical
condition
areas and
and set
set standards
standards
areas
Identify breakdown types
Identify breakdown
types
causes &
breakdown
analysis
countermeasures
2.Implement
from
actions and
countermeasures
syste
3.Set the planned
4. m
Set the Machine
maintenance
Board
1. Introduce
a
new
breakdown
definition
to improve the data
collection system
2. Introduce the breakdown
3. Define the system to
analysi s sheet
support it
4. Train all the relevant
operators and
maintenance technicians
5. Implement the system &
continuously follow up
2. analyses
Perform Initial
and results
Cleaning and Tagging
1.
areas
3. Identify
Manage critical
the
4. Define and Implement
Tags
Cleaning, Inspection and
Lubrication standards
5. Restore all the
Operating
Standards
Date/sh
ift
Produc
t.
Operat
or
Mainte
n.
Techni breakdo
c.
wn
Tim
e
machi
interventi
ne
on
machi
resta
ne
rt
Compone
nt faile
d
Failur
emod
e
Fixin
g
interventi
on
Long
term
countermeas
ure
Com p.
2
4
2
Filler
Com p.
4
10
1
5
20
15
Comp .
1
2
0
30
4
0
50
Comp .
2
13
Comp .
3
Source: 20
weeks
1
0
Number
of breakdowns 6
PACKER
2
0
Palletiz
er
2
0
Labelle
r
10
Com p.
3
3
8
Packer
20
Com p.
1
Comp .
4
8 5
1
0
1
5
25
Attack repetitive
Attack
repetitive
breakdowns
breakdowns
Failure
Modes ?
2
0
Comp.
2
1
0
Comp.
3
Comp.
4
6
0
1
0
1
5
2
0
2
5
smashed by a
foreign body
lack of preventive
maintenance:
changing impeller
before end of
useful life was not
considered
Impeller falls of
4th
why
1.1.1.1 Too
Pattern mend 1. Heald wires 1.1 Too much 1.1.1 Heald
wires
Problem broke on
1stwide
whystress on
2nd
whylocks and
3rdbreaksmuch
required
the
in vibration
central
loom
wires
the heald
why
in the
zone
(mainly in
frames
the
cente
r)
1.2.1.1
not
Knotters
trained
1.2.1.2. May
not be part
spe
of job
c.
5th
why
1.1.1.1.1 No
wide
heald
support
for
frames
Actio
n
1.1.1.1.1
all the
Resetting
frames
according to
design
the
specs
1.2.1.1
Retrain
knotte
rs
1.2.1.2. Check
job
specif., add
one and
new
train
knotters
Owne
r
Plann
ed
JT/
PW
JP7/
W1
MH
P6W
4
MH
P6W
4
Heald
frame
Befor
e
No central
support
Problem:
On wide looms, there is
greater vibration and
stresses experienced on the
heald frame. This sometimes
causes a heald wire to break
which, in turn, may require
pattern mend.
Solution:
By fitting a central support to
the frame, vibrations are
greatly reduced and the
number of pattern mend also
reduced.
Heald
frame
Afte
r
With central
support
5W
Ye s
Acti on
n.
1
Ow
ner
WS
Expected
date
May 31
xxxxxxxxx
MG
May 31
xxxxxxxxx
LS
June 10
xxxxxxxxx
LS
June 10
5
6
xxxxxxxxx
xxxxxxxxx
WS
LS
May 31
June 10
Actual date
Jun 10
e
Jun 10
e
Jun 10
e
Jun 10
e
May31
Jun 10
e
Highlight the
the causes
causes of
of
Highlight
sporadic
sporadic
breakdowns
breakdowns
The
The system's
system's
ability
ability to
to be
be
restored
restored and
and
maintained
maintained in
in
its
its
operatio
nal
condition
conditio
s
ns
Time of
breakdown Time
of intervention
Time to repair
Time to start-up
11.04
12.23
3 hours
Production
Operat.
M aintenance
Techn.
Team
16.00
Sketc
h
Stat
or
loss
Vibratio
n Greaseof
Descr.
lea k
Air
cooling
Green
White
Yellow
Insulatio n
covered by
grease and
carbon black
Roto
r
Use the back of the sheet for 5 why analysis on the failure mode identified (Operator +
Maintenance Technician)
Roo t causes
"Earthing" failure o n brush bar
Cat.(*)
2
Countermeasures
Install a filter a nd ma ke preventive checks (every
week)
Repla ce bearing with a leak-proo f one
By whom
Electrical
technicians
Frequency
Monthly during the PM shutdown
By whom
Electrical
technicians
Electrical
technicians
Electrical
technicians
(*) 1. Design faul ts 2. Lack of preventive maint. 3. Previous quick fix 4. Incorrect prod. operation 5.
Spare part quality/availabilit y
breakdown
Understanding
1
3
4
Ma
Ti m e o f breakdo wn
chi ne
Da
Ti m e o f int ervent i on
te
Shi
Ti me t o repa ir
Wha t ha ppened
and wh ere ( sect io
ft
n/subassem bl y)
Ti me to start
-up
Te am
Use the ba ck o f the she et for 5 why a nal y si s o n the fai l ure mo de ide nti f ied ( Operato r + M
ai ntena nc e T echni c ia n)
Ro ot c a us es
C a t .(*)
C ou ntermea s ur es
B y wh om
Freq uen c y
( *) 1. Desi g n fa ul ts 2. La ck o f pre ventiv e mai nt . 3. Prev io us qui ck f i x 4. Inco rrect pro d. ope ra ti o n 5.
Spare part qual i ty /a va i l abi l it y
Ba
The extruder
d stops
Goo
The electrical
d motor failed
Ba
d
Goo
d
Air
cooling
Insulation
coveredand
grease
by carbon
black
Stat
or
NO
SKETCH
Roto
r
Leaks of grease
beari
from
ng
Electric
failu
motor
re
Roto
r
Roto
r
Grease leaks
bearin
from
gs
Stat
or
Electric
failu
motor
Cooling
re
air
air cooling
bar
system
Stat
or
Electric
failu
motor
re
NO
SKETCH
Electric motor
Carb
on black entering on Broken
failure
brush
Grease
fr om
leaks
bearings
FINALLY, well-done
sketches are produced:
Complete, essential,
containing all remarks
needed
to understand
VERY
what
GOOD !
happened!
After repeated requests, a technical drawing taken from a Supplier or from the
Technical Office is shyly produced: you understand a little more, but it is still not
enough.
GO BEYOND !
At the beginning, nobody dares to draw a sketch: people are ashamed of not
being good at drawing. OVERCOME THIS PHASE IMMEDIATELY!
Insulati
covered
on
with
grease
carbon
an d
black
broke down?
Vibration
Oil leaks
Noise
of any sort?
Yes
No
Speed loss
Defects
Noise
.....
Ba
I repaired the
d motor by
Goo
Bearing replaced
d
Why
3
Why 1
Why
4
bar replacement
bar
replacement
every 66 months
months
every
Goo
Proble
d
Them
motor
stopp
ed
Why
1
1.
Ground
breakdown
brush
on
bar
Actions
Action
s brush
Preventive
brush
Preventive
Preventive
Preventive
replacement every
every
replacement
3
months.
3 months.
Why
2
1.1 Insulation
Why
3 black on
1.1.1 Carbon
Why
4
1.1.1.1 No
Actions
Action
s
Filter replacement
replacement
Filter
loss
brush
bar through air cooling
system
filter
and preventive
and
preventive
check
check (weekly)
(weekly)
1.1.2 Grease
Grease leak
leak from
from
1.1.2
main bearing
main
beari
ng
1.1.2.1 Bearing
Bearing
1.1.2.1
is not
not leakproof
is
leakpro
of
Bearing replaced
replaced
Bearing
with aa leakproof
with
leakproof
one
one
Ba
No suggestions
d
Goo
Install leak-proof
d bearings (dry bearings)
Install air cooling filters
Electric motor filter inspection standard
break ?
Why did that specific
component break?
What about the stress
applied on that
component?
Why was that stress
applied on that
component?
What are the
requirements to prevent
this breakdown?
Who takes the
responsibility of the
above said breakdown
prevention? When? How?
prevented through
symptomatic analysis?
How can symptoms be
identified?
What kind of skills and
abilities are required the
operator to identify the
event?
appearance?
Is this breakdown mode usually linked to these
anomalies?
Why in this case weren't any breakdowns detected?
Which is the simplest way to pay attention to
symptoms?
Which knowledge and skills enable the operator to
Electric
Mechanic
..
Intervention type
Replacement
Restoration
..
restoration
happen?
Mechanic
Electric
Corrosion
Vibration
it?
activities?
smashed by a
foreign body
machine failure?
Vibration
Oil leakage
..
Yes
No
Speed losses
Defects
Noise
..
symptoms?
Impeller falls of
lack of preventive
maintenance: changing
impeller before end of
useful life was not
considered
human error: some
operators are not able
to fit impeller correctly
impeller smashed:
design fault: no
protective screens
have been provided
Countermeasure
Design fault
Design modification
related?
conditions?
an equipment diagnosis?
Predictive maintenance
Suggested actions
Machine re-design
6
7
Breakdown mode
Wear part
Adhesive part
3
4
5
Jammed part
Broken part
Loosened part
6
7
8
9
10
11
Fold part
12
13
14
15
16
Broken wire
17
Steam leakage
Water leakage
Air leakage
Oil leakage
Machine contact or weak electric
Loosened wire
Overload
Insuficient insulation
Burn-out
3
4
5
Breakdown general
data, what
happened, prior
signs
Component failed, failure
mode, fix intervention,
spare parts
Who
Operator
Maintenance Technician
& Operator
When
At the time of breakdown
Team
Team
Daily
4
3
2
Count. followup
Nam
e:
Job:
Date:
Asse
ssors
:
Train
er:
Dave Ford
Mainten.
operator Nov
20, 1996
XX
YY
ZZ
John Smith
Coun
t.
plann
Befor
e
traini
ng
After
traini
ng
Fix
interventi
on
5Why
Analy
sis
Targ
et
He knows the
He s
theory
informed
He can do it in practice, in
working
standard
conditions
He can do it very well, also
in non
standard working
condition
He can teach / coach other
people
3
4
5
Classroom
Courses
General
Information
On the job
training
Advanced
training
(on
potential
problems)
How to train people
course
Step of
Step of
defect
defect
analysis
analysis
Breakdown general
Breakdown
general
data, what
data,
what prior
happened,
happened,
prior
signs failed,
Component
failure
signs failed, failure
Component
mode, fix intervention,
mode,
fix intervention,
spare parts
spare parts
Root cause analysis (5
Root cause analysis (5
why's)
why's)
Countermeasure
Countermeasure
identification
identification
and plan
plan
and
Implementation
and follow
Implementation
and
-up
follow -up
Production
operator
Production
operator
3
3
Maintenance
operator
Maintenance
operator
3
3
2
3
4
4
3
3
4
4
2
3
4
4
3
3
4
4
3
2
1
0
1st
week
Occ urred bre ak
downs
An al ysi s wi th
c/meas. im pl.
2nd
week
3rd
week
C ompl eted
analysis
A na lysis with c /me as. i
nef fe ct .
4th
week
An al ysi s wi th c /me as. i
den tif .
Define preventive
preventive
Define
maintenance
maintenance
plans
plans
3
Root
Cause
2
Compone
nt
1
Failu
re
4
Countermeasu
res
Countermeasure
Design fault
Design modification
Preventive maint.
Quick fix
activities
Incorrect production
operation Spare part quality /
Lack of spare parts
Maintenance training
Production training
Improved spare part
management system
19
21
20
37
38
22
39
4
40
23
27
24
1 42
53
25
26
28
43
44
12
13
14
45 46
15
16
17
18
cheap
easy
access
introduction
easy modification &
improvement
29 30
limited
visibility 32 33 34 35 36
bureaucracywith parts
connection
performance and life.
47
48
49
50
51
52