Duration
1 day
Overview
To improve any production process, efficient and effective equipment need to be sustained at an optimum condition. The equipment must be able to run smoothly with Zero Downtime and produce Zero Defect. Such a condition can only be achieved if a proper setup on plant maintenance is done. Today's megatronic equipment need an effective and efficient method of maintenance. Conventional Breakdown and Trial and Error method is not cost effective maintenance for today's machines and equipment. We need a proper system of Preventive and Predictive Maintenance Practices (Main essence of Total Productive Maintenance (TPM)) to ensure Zero Breakdown for the machines. This will enhance our company’s profitability, competitiveness and economy growth.
Objectives
After Attending this session, participants should be able to:
- Understanding the concept and culture of Total Productive Maintenance (TPM)
- Establish a Machine and Equipment maintenance table to ensure Zero Breakdown for the machines.
- Implement the necessary action to ensure Predictive Maintenance achieve the appropriate result.
- Design checklist for proper predictive maintenance for their machines.
- Apply wherever applicable, the techniques for Predictive Maintenance on selected machines.
Contents
- Introduction to Total Productive Maintenance.
- What is Total Productive Maintenance (TPM) ?
- Concept and culture of TPM.
- Relationship between Maintenance and Production.
- Rules for Machine and Equipment Design.
- Different type of Maintenance.
# Breakdown Maintenance.
# Routine Maintenance.
# Corrective Maintenance.
# Preventive Maintenance.
# Predictive or Condition Based Maintenance.
# Productive Maintenance.
# Total Productive Maintenance.
# Value Added Maintenance Activities.
- Comparison between Preventive and Predictive Maintenance System.
- Time Based Maintenance
- Cycle Based Maintenance.
- Condition Based Maintenance.
- Workshop: Decide the matrix to carry out Preventive and Predictive Maintenance for selected machines.
- Preventive Maintenance implementation.
- Preventive Maintenance Activities.
- Improving the machine/equipment for easy and effective maintenance.
- Maintenance cost tracking.
- Data recording and Machine behavior studies.
- Exercise & Workshop: Develop implementation matrix for machine maintenance.
- Predictive Maintenance.
- Essence of Predictive Maintenance – Technical & Economic Consideration..
- 5W 1H for Predictive Maintenance Implementation.
- Tools and Techniques for Predictive Maintenance:
- Monitoring with statistical methods for tool life data analysis
- Application of Vibration Meters for Bearings.
- Application of Infra Red Thermography for Electrical Switch boards and other heat sensitive equipment.
- Monitoring of air pressure, hydraulic pressure and other critical parameters in the machine to determine the machine health proactively.
- Application of Feeler gauges, deformation gauges and other mechanical measurement to detect threshold value for wear and tear.
- Checklist to perform Predictive Maintenance Activities.
- Improving the machine/equipment for easy predictive data collection, analysis and maintenance.
- Maintenance cost tracking.
- Develop improvement plan for machine’ future maintenance activities.
- Exercise and Workshop: Using the Saw blade worn out data provided, perform a simple statistical analysis and develop the expected life to change the blade before failure.
- Effects of Preventive Maintenance & Concluding Remarks.
- Tracking of machine/equipment life time and quality performance improvement.
- Develop Maintenance Effectiveness Evaluation Plan.
- Set up your own implementation plan.
- Conclusion and Q & A.
Training Methodology
This course will be conducted in the form of lecture, exercises and group discussion. Ample exercises will be given. Participants will involve in setting up to their own maintenance plan which will enhance their understanding and practical hand-on knowledge.
Who Should Attend
The target audiences include ALL Technical Executives, Technicians or any one who are interested to know or need to apply Maintenance Techniques.
Benefits from this course
This course intends to bring the following benefits to all participants:
- Understand the history and evolution of maintenance methods.
- Develop a habit of value-added maintenance activities.
- Cultivate a root cause solving attitude.
- Develop a systematic approach of solving problems.
- Using the effective maintenance approach to drive down machine failure time and also to improve productivity.
- Perform maintenance job in a systematic and effective way.
- Making his job or contribution to his organization more significant.
Programme scope, delivery arrangements and suitability are confirmed during enquiry.