Professional Documents
Culture Documents
2/9/2009
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2/9/2009
Integrated
Planned
M aintenance
World Class
Maintenance
Failure Evaluation
Continuous Improvement
Reliability Engineering
Shop Stores
Inventory
Maintenance
Organization/
Structure
MaintenanceTM
Excellence
Personnel
Skill/Training
Work Control
Maintenance
Planning
Scheduling
Equipment
Database
CMMS
Management
Support & Measures
of Effectiveness
Maintenance
Tasks/Procedures
( Maintenance
Management
MM
( Maintenance
Management
) )
Strategy
Worldclass
Module 1
: Development of Maintenance
Module 2
: Maintenance Planning
Module 3
: CMMS
Module 10
: Inventory Management
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2/9/2009
FA
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2/9/2009
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10% - 40 %
70 %
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2/9/2009
T a rg e t
TPM
Cost
Q u a lit y
E q u ip m e n t
MMS
4 Ms
R C M/ Uptime
Teamwork
RCM
Data
Measures
Management
Strategy
TPM
Tactics
Continuous
Improvement
Plan
and
Schedule
Control
Management
Leadership
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#1
Maintenance
2
5
4
7
10
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Maintenance Organization
-
1
-
1
-
2
-
2
-
-
# 2
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Worldclass
Stage 5
Operational Excellence
Asset
Management
RCM
Reliability
Focus
QCC
Craft
Fixibility
5S
TQM
Equipment
Simplification
Standardization
Failure Mode
Analysis
PdM
CMMS Integration
Enhancement
Craft Skills
Preventive
Work Management
Maintenance
Processes
Prioritization
Engineered Reliability
Maintenance
AsExternal
Operations
TPM
Integratiom Benchmarking
Predictive
Maintenance
Work Initialion/
Stage 4
Concurrent
RAM
Engineering
Analysis
Life Cycle
Analysis
Planning
& Scheduling
Stage 3
Organizational Excellence
Proactive
Maintenance
Stage 2
Proactive Maintenance
Equipment History
Work Execution/
Review
CMMS
Materials
Management
Stage 1
Daily
Maintenance
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Discipline
Uptime
Uptime
A sset
E n v iro n m e n t
B u s in e s s
S tra te g y
G lo b a l O b je c tiv e s fo r
P la n t E n g in e e rin g a n d M a in te n a n c e
C u rre n t
S ta tu s
P e rfo rm a n c e
G ap
V is io n
P e rfo rm a n c e
D riv e rs
M is s io n
M a n d a te
G u id in g
P rin c ip le s
C
Coonncceeppts
ts
O
Org
r gaanniz
izaatio
tionn
A
ra nnggeem
Arrra
m eennts
ts
Ta c tic s
EEdduuccaatio
tionn,,
Tr
a in
Tra
inin
ingg
M
Meeth
thooddss,,
To
Toools
ls
SSys
yste
tem
m ss,,
PPro
rocceedduure
ress
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2/9/2009
Uptime
M aintenance
P rocess
P eengineering
P rocess
S tratrgy
Leadership
P lanning and
S cheduling
M ateriais
100
M anagem ent
80
H um an R esources
60
40
20
20
40
60
100
E m ployee
M aintenance
Tactics
Inform ation
Technology
System s
80
P erform ance
M easures
R elliability
A nalysis
M ethods
Q
( Breakdown Maintenance : BM )
Q
( Preventive Maintenance : PM )
Q
( Maintenance Preventive : MP )
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2/9/2009
Q
( Total Productive Maintenance : TPM )
Q
( System Maintenance : SM )
# 3
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2/9/2009
:
M a c h in e / Q T Y
S u b m e r s ib le P u m p
C o ld w a te r P u m p
C h ille r P u m p
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29
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11
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29
16
11
M a c h in e / D a te
S u b m e r s ib le P u m p
C o ld w a te r P u m p
C h ille r P u m p
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2 .6 6
2 .6 6
2 .6 6
M a c h in e / D o w n c o u n t
S u b m e r s ib le P u m p
C o ld w a te r P u m p
C h ille r P u m p
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1
2
3
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1
1
15
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1
1
16
M a c h in e / D o w n tim e
S u b m e r s ib le P u m p
C o ld w a te r P u m p
C h ille r P u m p
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3
8
88
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3
5
114
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4
4
119
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6 .5
6 .5
6 .5
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16
11
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6
6
6
MTTR =
MTBF =
Machine Efficiency =
MTBF
MTBF + ( MTTR / 60 )
24
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X
X
X
A =
( Availability performance )
P =
( Production Speed Performance )
Q =
( Quality Performance )
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: ( loading time
) 1 460
20 20
20
60 400 ( 460-60 = 400 )
2
1.25
400 8
( Loading time )
= - x 100
= x x 100
= - x 100
: = 0.5 / ; = 0.8 /
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2/9/2009
: 100 HP 3 380 v. 50 Hz
50 ( 1999 )
P.M.
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Circle of Improvement
W HY
RESULTS
W HAT
RCM , TPM , RCFA,
Prognosis
HOW
W ork Planning/Scheduling,
Task Instructions, Tools,
Safety Precautions, Parts Requirem ents
W HEN
PM
Predictive /Condition
X Schedule X Vibration
X Lube O il
Failure
X Therm ography
April 1998
X Etc.
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)
Q
Q
Q
Q
)
Q
Q
Q
Q
Q
Q
22
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)
Q
( Preventive Maintenance )
Q
)
Q
Zero Defect
23
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10
Q
Q
Q
Q
Q
10
Q
Q
Q
Q
Q
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Q
Q
Q
( 8 Modules )
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( 8 Modules )
Q
Q
Q
Q
Hydraulic
Pnuematic
Q
Q
Q
Q
( Normal operation )
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Q
Q
- Advance PLC
- Debug ( Card repairing )
- Programmer
Q
16
( 16 )
Loss 5
( )
Operating manhours
MH
9.Management loss
10.Operating motion loss
Loading manhoure
Production
manhours
loss
Startup loss
Overload loss
Temp./Heat loss
Line
organiaztion Effective manhours Net operation
time
manhours
loss
Defect in Valued Valued
manhours manhours operating
time
loss
manhours
( )
15.Energy loss
( )
Working hours(365x24)
Loading time
Down
Operation time time
loss
Effective energy
( )
( , )
16.Die, Tool&Jig loos
Die, Jig, Tool
8.Shutdown loss
1.Breakdown loss
2.Setup&Adjustment loss
3.Part change loss
4.Start-up loss
Down time loss
5.minor stoppage and idling
6.Speed loss
7.Defect and rework loss
Defects loss
Start-up
Cutting loss
Loss in weigh
Loss in overage
(Increased commission)
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:
1.
2.
3.
4.
3
PM
operator
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Zero
Failure
2
4 M
Man
Machine
Method
Material
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-
-
30
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MTTR / MTBF
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Q
Q
Case study
Name
1 2
A A
B B
C C
D D
Machine
3 4 5
A B B
B B C
D D D
D D D
Target
100,000 baht
reduce 80,000 Baht
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2/9/2009
C M M S
Pr
od
uc
tio
Fi
ng
ni
na
an
nc
Pl
ia
ls
n
an
d
C
on
t ro
l
Preventive
Maintenance
Planning and
Scheduling
Maintenance
Database
Equipment
History
D
A
um
an
Costs
and Budgets
/C
Labor
ou
in
g
es
AE
Inventory
Control
em
En
st
Sy
gi
ne
er
rc
Condition Measurements
Maintenance Management
Decision Support
Data
Information
MIMOSA
Equipment Management
Information Model
thanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
November, 1997
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2/9/2009
Decision Support
Xoperating measurements
Data
Xcorrosion thickness
Information
MIMOSA
Equipment Management
Information Model
thanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
Maintenance Management
Condition Measurements
Data
Data:
Data:
XXIDs:
IDs:Plant
Plant/ /Location
Location/ /Equipment
Equipment
XXEvents
Events
XXNumerical
Numericalvalues
values(measurements)
(measurements)
XXMeasurement
Measurementtrends
trends
XXArray
/
Image:
Array / Image:
Vectors
Vectors
Time
TimeWaveforms
Waveforms
Orbits
Orbits
Spectra
Spectra(frequency,
(frequency,order,
order,CPB)
CPB)
Lube
Lubeoiloilparticle
particle
Temperature
Temperatureimages
images
Information
MIMOSA
Equipment Management
Information Model
thanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
November, 1997
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2/9/2009
Maintenance Management
Condition Measurements
Decision
Support
Xworkforce management
Xscheduled maintenance
(inc. PM)
Xwork management
XMRO inventory management
Xtool and rental equipment
Data
Xcost accounting
Information
MIMOSA
Equipment Management
Information Model
thanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
November, 1997
Condition Measurements
From
Decision Support
FromMaintenance
MaintenanceManagement:
Management:
XXConditions
found
Conditions found
XXSpare
Spareparts
partsavailability
availability
XXWork
accomplished
Work accomplished----Action
Actiontaken
taken
XXMaintenance
history:
work
Maintenance history: workperformed,
performed,cost,
cost,
process
processdowntime
downtime
Data
XXNameplate
Nameplatedata
data
XXManufacturers
Manufacturersspecifications
specifications
XXWork
Workorder
orderissued:
issued:Work
Workorder
ordernumber,
number,
requirements:
parts,
resources,
requirements: parts, resources,tools,
tools,people
people
XXWork
Workschedule
schedule
Information
MIMOSA
Equipment Management
Information Model
thanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
November, 1997
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2/9/2009
Maintenance Management
Condition Measurements
Decision Support
Xmechanical diagnostics inc. rolling bearing
Xperformance/efficiency
Xreciprocating analysis
Xoperating deflection shape (ODS)
XrootData
cause
Xreliability centered maintenance (RCM)
Xrisk
Xprognosis
Information
MIMOSA
Equipment Management
Information Model
thanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
November, 1997
Maintenance Management
Condition Measurements
Decision Support
Information
Information
XXStatus
Status----something
somethinghappened,
happened,event
event
XXState
Stateofofhealth
health----numerical
numericalcondition
conditionindex
index
XXRate
of
change
(health/severity)
-numerical
Rate of change (health/severity) -- numerical
Data
XXTime
Timetotoaction
action----predicted
predicteddate
dateunder
undercurrent
currentconditions
conditions
XXProblem
Problemidentification
identification----description
description
XXComponents
Componentsaffected
affected----description
description
XXRecommendations
Recommendations----operating
operatingand
andmaintenance
maintenance
XXRemarks/Comments
-explanatory
Remarks/Comments -- explanatoryinformation
information
XXWork
Workrequest
request----yes
yesorornono
XXConfidence
Confidence----numerical
numerical
MIMOSA
Equipment Management
Information Model
thanks to: Ken Bever, John Hawkins, Alan Johnston, Art Jones, Peter Morgan
Information
November, 1997
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2/9/2009
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2/9/2009
M a in te n a n c e
In s p e c tio n
P re d ic tiv e
P re v e n tiv e
CBM
C o rre c tiv e
L u b ric a tio n
M a te ria ls
E q u ip m e n t
C o n tro l
Id e n tify
E q u ip m e n t
C o n fig u ra tio n
S o u rc e
O rd e r
P la n
Net
C a p a c ity
S p e c ify
B ill o f
M a te r ia ls
S c h e d u la
S to re
C o n tro l
A s s ig n
R e p a ira b le s
E x e c u te
U se
A n a ly z e
A n a ly z e
R e p o rtin g
Historical Data
CMMS
Recommendations
Expert System
Action
New data
CBM
Vibration
Temperature
Oil Analysis
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2/9/2009
Category
Category
Increase
Capacity
Goal
Business Objectives
Improve Availability
Reliability, and
Maintainability
System
System Objective
Objective
Reduce failures
Reduce stoppages
Reduce speed
Reduce variance
Build PM routines
reduce work
Perfomance monitering
Reduce labor
Control jobs
Plan labor/materials
Analyze usage
Analyze investment
Schedule PM
Analyze breakdowns
Automate work oders
Automate POs
Costs by area, job, type
of expense, labor
Reduce
Costs
Reduce Overall
Maintenance
Costs
Reduce emergencies
Reduce paperwork
Perfomance monitering
LAN
LAN
LAN
Montreal
Barrie
LAN
Etobicoke
National
LAN
Vancouver
LAN
Edmonton
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2/9/2009
Demming
Q ( Plan )
Q ( Do )
Q ( Check )
Q
( Action )
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2/9/2009
X
X
X
X
X
X
X
X
X ( )
X
X
X
X
X
X
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2/9/2009
:
X : Log Out
K eys
:
X : Tag Out
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:
Q 3 Rs
X Reduce
X Reuse
X Recycle
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# 4
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:
Q
X ( )
X
X
X
X
X
:
Q
X
) Master Planning /
) 5W 2H
)
)
)
)
)
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:
Q
X
X
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2/9/2009
Plant Data
?
( P.M. Instruction )
?
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Q 4
X
X
X
X
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Q
Q
Q
Q
Q
Q
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( Inventory Management )
Q 3
X ( ROP )
X MRP
X ( JIT )
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( Inventory Management )
Q
X
X
~15%
) STOCK
)
X
Lead time
X
( CMMS )
X Work order control system
X P.M. system
X Stock control management
X Purchasing control
X OMM ( Optimum Maintenance Mix )
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Q QC 7 Tools
Q Why - Why Analysis
Q Failure Analysis
Q P- M Analysis
Q Kaizen
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Date of occurrence
D/M/Y
Downtime
Failure
Classification
OK/NG
Results
Persult of causes
1. Why? ( cause of
investigation results
Measures
4. Why?
( cause of 3)
5. Why?
( cause of 4)
Equipment , parts
Persons
Prevention of recurrence
Comments of manager
Schedule ( / )
Completion ( / )
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