BASIC MAINTENANCE

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BASIC MAINTENANCE
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• DEFINITION MAITENANCE
• The act of maintaining or the state of being
  maintained.
• The work of keeping something in proper
  condition upkeep.

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• The Operators can find an abnormality
• They can Perform Daily Checking
• They can judge an abnormal condition
• They fully understand the structure and function
  of the facility
• They can detect an abnormal condition using their
  five senses

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• The operators can deal with the trouble and
  perform the recovery
• They can make an improvement
• They can recover (repair) the malfunctions

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• The operators can create the judgment standard
• They can create the checking standard by
  themselves, and can both check the equipment and
  instruct junior staff on how to perform the check

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The operators can examine the cause of trouble -
They can think about WHY? when a loss or
abnormality occurs.
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Productive Maintenance - is a technique for
allowing production system to exert its
capability to the maximum.
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Preventive Maintenance
Maintenance Activities
Breakdown Maintenace
Productive Maintenance
Corrective Maintenance
Improve Activities
Maintenance Prevention
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• What Is Preventive Maintenace
• Daily Maintenance to Prevent Deterioration(cleanin
  g, checking, lubricating, tightening bolts)
• Periodic Inspection and Facility Diagnosis
• Maintenance for recovery

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TBM( Time Based Maintenance) Time Based
Maintenance is the methode whereby maintenance is
carried out in a fixed cycle determined by the
mean time between failure(MTBF) and other
factors. Fixed Cycle
Inspection , Repair Replacement, Renewal
Inspection , Repair Replacement, Renewal
Inspection , Repair Replacement, Renewal
Inspection , Repair Replacement, Renewal
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CBM (Condition Based Maintenance) Also referred
as prediction maintenance. This is a method
whereby facility deterioration is constantly or
periodically monitored by facility diagnosis and
maintenance is conducted when an abnormality is
found. Monitoring Predicting and foreseeing
the deterioration quantitatively (When an
abnormality found) Inspection,Repair Replacement,R
enewal
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• Breakdown Maintenance
• is carried out after breakdown has occurred.
• No failures frequently
• No serious effect with short time failure
  shutdown
• Where spare or replacement available
• Not so important

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CM (Corrective Maintenance) Is the maintenance
work which improves the existing facility to a
state where it is free of breakdown(reliable),
easy to check and repair(good Maintenance), easy
to operate and operates safety.
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MP(Maintenance Prevention) - design must be
created by examining the maintenance information
so that the facility can be free of failures,
repair immediately even if a failure occurs, easy
to operates, safe for operation, and incurs low
cost.
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TPM(Total Productive Maintenance) - activities is
that everyone participate in multiple activities
in small groups and the operators themselves are
responsible for carrying out the
maintenance(voluntary maintenance activities).
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• Why everyone should participate in Productive
  Maintenance?
• to keep the production equipment running
• the operator in charge of operating the machine
  must be responsible for the maintenance of the
  machine.
• The engineers in charge of design and development
  of facilities and products.
• Efficiency even in indirect department such as
  accounting and sales should also be increased.
• Attitude to look after their own facility by
  themselves

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Six Major Losses Loss due to failure Loss due to
arangement Loss due to idling and short
shutdown Loss due to speed reduction Loss due to
defect and correction Loss due to starting up and
yield
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• From forced deterioration to natural
  deterioration
• It will happen naturally, but in reality many
  facilities deteriorate due to incorrect
  handling(called forced handling)
• Example of force handling
• Neglecting to apply lubricating oil caused the
  parts to wear out.
• Refuse or dust entered into rotating part or
  maving part and caused these parts to wear out.
• A cooling fan is heated up by the clogging of
  dust.

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For Zero Failure Maintenance of basic
Condition Observe the operating condition Recover
deterioration Increase operating and maintenance
skill