Module 2
Module 2
PREDECTIVE MAINTENANCE
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PREDICTIVE MAINTENANCE
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How does predictive maintenance work?
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Six Pillar Of predictive maintenance
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➢ People: Every other pillar of a predictive maintenance program needs people
to build and maintain it. Data needs interpreting. Technology needs setting up
and managing. That’s why everyone in your organization should understand
how PdM works, why it’s important and what they can do to make it successful.
➢ Processes: Processes are the way you work—how your maintenance team
plans and does the things it needs to do every day to be successful.
Processes in a predictive maintenance program are people-driven and
equipment-driven.
People processes involve the way your maintenance team goes about their work.
They outline how staff interact with machines, data, each other, and everything
else.
Equipment processes involves to know what processes your equipment
completes, how to capture asset data, and how the data maps to future
performance.
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Six Pillar Of predictive maintenance
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➢ Tools and parts: Tools are the instruments used to measure the
condition of assets, like infrared cameras, and the tools needed to
inspect or repair equipment. Parts are the different components of
equipment, but not just any old parts will do for predictive
maintenance
Applying predictive maintenance to your most critical assets with the most
observable failure modes because of the time and money needed to build a
PdM program.
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Condition Based Maintenance (CBM)
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Principle of CBM
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❑ Trend monitoring
▪ This is the continuous or regular
measurement and interpretation of data,
collected during machine operation, to
indicate safe and economical operation.
❑ Condition Checking
▪ In which particular or instant condition is checked while machine is
running and readings can be taken
▪ Then this is used to analyze machine condition.
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METHODS OF CONDITION MONITORING
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❖On line – speed, temperature, vibration and
pressure
❖Off line – crack detection, thorough check of the
alignment, state of balancing, corrosion and pitting
Visual monitoring
Vibration monitoring
Temperature monitoring
Lubricant monitoring
Leak detection
Noise monitoring
Corrosion monitoring
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1.Visual Monitoring
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2.Vibration Monitoring
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Rotating equipment such as compressors, pumps and motors all exhibit a
certain degree of vibration. As they degrade, or fall out of alignment, the
amount of vibration increases. Vibration sensors can be used to detect when
this becomes excessive.
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2.Vibration Monitoring
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3. Temperature Monitoring
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The Temperature Monitoring sensitive aspects of a unit can
be readily monitored. These include contact Thermometers,
Thermocouple, Thermistor, Temperature chalks and paints
and infrared detectors (IR Cameras).
➢ Bearing damage
➢ Failure of coolant
➢ Incorrect heat generation
➢ Build-up of unwanted materials
➢ Damage to insulating material
➢ Faults in electrical components
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3. Temperature Monitoring
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3. Temperature Monitoring
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4.Lubricant/ oil Monitoring
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4.Lubricant/ oil Monitoring
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5. Leak Detection
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6. Noise Monitoring
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6. Noise Monitoring
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6. Noise Monitoring
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6. Noise Monitoring
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6. Noise Monitoring
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6. Noise Monitoring
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7. Corrosion Monitoring
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8. Wear Debris Monitoring
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7. Wear Debris Monitoring
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7. Wear Debris Monitoring
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7. Wear Debris Monitoring
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CBM = Cost Savings + Higher system reliability
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Advantages
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Disadvantages of CBM
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Vibration Analysis
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Vibration monitoring techniques can be chosen depending upon time, effort,
level of sophisticated and cost.
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Faults
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Vibration Based Condition Monitoring
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Time Domain Analysis
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Security Level
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Frequency Domain Analysis
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GEAR BOX
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Time Domain Analysis
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GEAR Fault Frequencies
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Frequency Domain
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Fault is at wheel
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Total Productive Maintenance
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Overall Equipment Effectiveness (OEE)
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Overall Equipment Effectiveness (OEE)
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Total Productive Maintenance
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A company-wide team-based effort to build quality into equipment and
to improve overall equipment effectiveness
Total
•Participation of all employees
•Include all departments, operation, equipment and process.
Productive
•Pursue the maximization of efficiency of the production system by making all losses
zero.
•Zero breakdowns, Zero accident, Zero defects.
Maintenance
•To improve the efficiency of the equipment
•Keep the man-machine-material & system in optimum condition in the entire
life cycle of the production
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TPM Evolution
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History of TPM
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Definition
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PILLARS of TPM
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PILLARS of TPM
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1 S – Sorting
1.Not Needed at all
2.Needed but not now
3.Need but not here
4.Needed but not so much quantity
Criteria:
• Obsolete
• Defective
• Scrap
• Not in place
• Unnecessary
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2 S – Set in Order
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2 S – Set in Order
Search Free
& Count Free
Visual
Management
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2 S – Set in Order
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3 S – Cleenliness
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4 S – Standardization
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5 S – Self Discipline
➢Daily Monitoring
➢Improving ownership by allocating areas
➢Using red tag campaign
➢Structured communication
➢Continuous training of employees
➢Periodic audits at all levels
➢Motivation through recognition
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PILLARS of TPM
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1 st Pillar: Autonomous Maintenance (Jishu hozen)
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• Train the operators to close the gap between them and the
maintenance staff, making it easier for both to work as one team
• The goal is to change operators from being reactive to working
in a more proactive way, to achieve optimal conditions that
eliminate minor equipment stops as well as reducing defects and
breakdowns.
• Standards are introduced for cleaning, inspection, tightening and
lubrication to ensure the conditions are sustained. 71
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Autonomous Maintenance
7 steps are implemented to progressively increase operators
knowledge, participation and responsibility for their
equipment.
❑ Perform initial cleaning and inspection
❑ Countermeasures for the causes and effects of dirt and dust
❑ Establish cleaning and lubrication standards
❑ Conduct general inspection training
❑ Carry out equipment inspection checks
❑ Workplace management and control
❑ Continuous improvement
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Benefit of Autonomous Maintenance
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1) It improves OEE.
2) Reducing performance loss and increasing equipment
availability.
3) Improvement to employee engagement and capability levels.
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Planned Maintenance (Keikaku Hozen)
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➢ Aimed to have trouble free machines and equipment
producing defect free product for total customer
satisfaction.
➢ It includes Preventative (Time-based maintenance) and
Predictive Maintenance (Condition Based maintenance)
system for equipment and tooling
❑ Natural life cycle of individual machine elements must be
achieved
❑ Lubrication
❑ Correct operation
❑ Retightening
❑ Correct set-up
❑ Feedback and repair of minor
❑ Cleaning defects
❑ Quality spare parts
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Planned Maintenance
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Activities of Planned Maintenance
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Benefits of Planned Maintenance
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Focussed Improvement (Kobetsu Kaizen)
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Focussed Improvement
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Process errors
Quality loss
Rework / scrap
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Distribution Loss
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Benefits of focused Improvement
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1)Improving Efficiency
2)Reducing Defects
3)It also aim to achieve 30% manufacturing
cost reduction.
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Quality Maintenance (Hinshitsu Hozen)
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Quality Maintenance (Hinshitsu Hozen)
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Aim: Achieve zero quality defects by sustaining correct
equipment conditions
Quality rate has a direct correlation with
❑Material conditions
❑Equipment precision
❑Production methods
❑Process parameters
Responsibility:
•Quality Assurance
•Production Engineering
•Research and development
•Maintenance Department 85
Quality Maintenance (Hinshitsu Hozen)
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Activities:
Quality Maintenance is implemented in two phases:
1. The first phase aims to eliminate quality issues by analysing the
defects, so that optimum conditions can be defined that prevent
defects occurring. Then, the current state is investigated and
improvements are implemented.
➢ Check quality standards and investigate existing quality.
➢ Check quality assurance condition and conditions prevailing in
process, raw material, equipment and methods.
➢ Identify, analyse and improve unsatisfactory conditions
➢ Establish correct 3M (Man-Machine-Method) condition and
inspection criteria
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Early Equipment Management (Shoki Kanri)
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Early equipment management is about what you can do before
maintenance happens (early; initial stage and control; management).
This pillar ensures the simultaneously developing the equipment
needed and the manufacturing process with the product design.
Focus on using previous experience to eliminate the potential losses
due to design through the planning, development and design stages.
Working with team on simultaneous activities so that quick start up
can be achieved with zero quality loss
It focuses on the design your machine to make
1) maintenance easier
2) Inexpensive maintenance
3) Infrequent maintenance
4) Have quick set-up times
5) Operate at the lowest life cycle cost
6) Safety 88
Early Equipment Management
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Aims
➢ to implement new products and processes with vertical
ramp up and minimized lead time.
➢ Achieve stable commissioning of new products and
equipment
Responsibility
➢ Research and Development staff
➢ Production and Engineering Staff
➢ Maintenance Staff
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Responsibility Early Equipment Management
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Maintenance Prevention
• Set development and design targets
• Set Manufacturing Standards
• Set Quality standards
• Set the standards for operations
• Set the standards for maintenance
• Set reliability standards
Other Activities
• Life Cycle costing
• Eliminate problems as design, drawing,
prototyping, fabrication, test-running, start-up
stages
• Perform design reviews 90
Education and Training
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➢ Aim:
• Boost the expertise of operator and maintenance
personnel
• Develop multiskilled employees
• Create the factory full of experts
➢ Responsibility:
• HR Personnel
• Maintenance Personnel
• Production Personnel
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Activities: Education and Training
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Benefits: Education and Training
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Office TPM
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Office TPM
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Aims:
• Achieve zero functional losses
• Create highly effective offices
• Provide effective service and support to the production
department
Responsibility:
• Team Leader and team members in office, sales and
other indirect departments
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Activities: Office TPM
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Safety Health and environment
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Aims:
• Achieve and sustain the zero accidents
• Create healthy, rewarding and pleasant workplaces
Responsibility:
• Safety, health and environment staff
• Machine operator
• Assembly/Production line leaders
• Quality Department
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Safety Health and environment
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Benefits:
1) Zero accidents
2) Zero health hazards
3) Zero fire
4) Safe working condition
5) Safe work practice
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Conclusion
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1. Autonomous maintenance improves the skills of operators and
empower him to take care the machine by him/herself
2. Planned maintenance stabilize the failure interval and extend the
equipment useful life
3. Focused improvement pillar identifies and eliminate the losses in
each area.
4. Quality maintenance ensures the zero defects condition for 3M
(Man-Machine-Material)
5. Early management starts right from the design of the equipment
and manufacturing process simultaneously with product design
6. Training and education assess the current skills of employees and
upgrade their skills to do the job in more effective and efficient way.
7. Office TPM support production and all other departments for TPM
implementation across the organization.
8. Safety, health and environment pillar ensures zero accident, good
health of employees and zero pollution (air, water, noise).
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