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The New TPM: Total Predictive

Maintenance
Publicado em 15 de maio de 2017

Shawn Rogers Seguir

13 0 10
ISO 9001:2015 / IATF 16949:2016 Auditor and Trainer

AddZUM/ZUDtoyouracronymvocabulary

ThisisanupdatetoapostinAugust2016discussingtheplannedTPM
requirementsexpectedtobeincludinginthereleaseofIATF16949:2016.

TheFuture:https://www.youtube.com/watch?v=Dw7qLw_A43QForsome
organizations,thisistheneartimehorizonforothers,itsbeyondthehorizon.

TheIATF16949:2016QualityManagementSystemstandardfortheautomotive
industrywasreleasedinOctober2016.Oneofthemanychangesinthestandard
expandedexistingmaintenancerequirementstowardatotalproductivemaintenance
program.ThejustificationgivenbytheIATFforexpansionoftheserequirementswas
evidenceofinsufficientmaintenanceimpactingthecustomer.

TheIATF16949:2016retainsalltherequirementofISO/TS16949:2009clause7.5.1.4
expectingtheorganizationtoidentifykeymanufacturingequipment,planmaintenance
activities,makeavailablespareparts,provideresourceformaintenance,ensure
packagingandpreservationofequipment,andusepredictivemethodstoimprovethe
effectivenessandefficiencyofproductionequipment.

Thenewstandardaddsrequirementsfordocumentedmaintenanceobjectives,providing
examplessuchasOEE(OverallEquipmentEffectiveness),MTBF(MeanTime
BetweenFailure),andMTTR(MeanTimeToRepair).Theregularreviewofthese
maintenanceobjectivesisalsoanadditiontothemanagementreviewinputs,requiring Entrar Cadastre-se
documentedactionswhenobjectivesarenotbeingmet.

Butwhatareeffectiveandefficientmeasuresofamaintenanceprogram?OEE,MTBF,
andMTTRarefinetraditionalmeasuresandfarmoreusefulthanthe%PMsDone
onTimemeasurealltoocommonlyused,thoughwidelyconsidered
ineffective.However,theseobjectives,whenputintopractice,oftenacceptalevelof
unplannedmaintenanceorinsomecasesdonotdistinguishbetweenplannedand
unplannedmaintenance.

Itsestimatedthatthetotalcostof
unscheduleddowntimecanbeasmuch
as15timesthatofascheduledevent.
Caterpillar

ZUM/ZUD

ThetrendamongleadersinmanyindustriesismovingtowardZeroUnplanned
Maintenance(ZUM)orZeroUnplannedDowntime(ZUD)asthemeansofdeveloping
andmeasuringtheeffectivenessandefficiencyofamaintenanceprogram.

ZUM/ZUDhasthegoalinthenamethatnounplanneddowntimeis
acceptable.BuildingamaintenanceprogramaroundZUM/ZUDcannotbedonewithout
asystematicimplementationofpredictivemethodologies.

Themostcommonpredictivemethodologiesutilizeperiodicsamplingofmachine
attributes.Examplesinclude:infraredthermalimagingofelectricaljunctions,acoustic
noiseanalysisofairhandlingsystems,vibrationanalysisofhighspeedmotorsorother
rotatingequipmentandoilanalysisoftransformersandhydraulicequipment.

However,ZUM/ZUDleadersareincreasinglyturningtocontinuousmonitoringof
machineattributestodeterminewhentoplanmaintenance.Utilizingstatisticalprocess
control(SPC)methods,thesemachineattributereadingswhendriftingtowardoroutof
acceptablelimitscantriggeraplannedmaintenancebeforethemachineisreported
down.Additionally,thismethodcanbeintegratedwithprocessperformancedataina
collaborativeprocessautomationsystem(CPAS)tointerdictbeforeadriftingmachine
willproducedefectiveproduct.

Deploymentofmachineattributemeasurementequipmenthasbeenaidedbythe
increasingavailabilityandaffordabilityofsensingandmeasuringequipmentandthe
useofwirelesssensornetworkstoreducewiringcosts.

TheuseofFailureModeEffectsAnalysis(FMEA)isparticularlyhelpfulindrivinga
ZUM/ZUDmaintenanceprogram,asstepstoachievezerounplannedmaintenancewill
alwaysrequirelearningcycles.Treatingeachunplannedmaintenanceeventinthesame
wasasapotentialprocessgenerateddefectdrivesthecontinualimprovement
 methodologyandjustificationforchangestothemaintenanceprogramtoachieveand Entrar Cadastre-se
maintainthezerounplannedmaintenancegoal.

Doyouhaveapredictivemaintenancemethodology?Whatmethodsdoyouuse?

Abouttheauthor:ShawnRogersisaCertifiedQualityManagementLead
Auditor,trainer,andconsultantwithmorethan30yearsexperienceinhigh
technologymanufacturingandproductdevelopment.Hehasextensive
experienceintechnologystartups,engineering,andbusinessmanagementand
qualitysystemsdevelopmentinbothsmallandlargeorganizations.Hehas
degreesinelectricalengineeringandbusinessadministration.

Shawn Rogers
ISO 9001:2015 / IATF 16949:2016 Auditor and Trainer Seguir
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