Principles of Industrial Maintenance PDF

Course materials provided for personal study only and subject to the disclaimer on the ECU website http://www.ecu.edu.au/supplemental/disclaimer Principles of Industrial Maintenance...

Course materials provided for personal study only and subject to the disclaimer on the ECU website http://www.ecu.edu.au/supplemental/disclaimer Principles of Industrial Maintenance Lecturer: Dr Ana Vafadar [email protected]  This lecture ⚫Coveragein this lecture will be largely derived from … Stephens, M. P. (2010) Productivity and reliability-based maintenance management. New Jersey: Pearson Education, Inc. (ISBN 9781557535924). Content from other sources will be indicated where applicable.  This lecture – the plan ⚫Thislecture material is largely based on … Implementing TPM (CHP 6) (Stephens, 2010) 6.1 Total Productive Maintenance 6.3 Unions and TPM 6.4The TPM Journey 6.5 Overall Equipment Effectiveness TPM Implementation and process Improvement Tools (CHP 7) (Stephens, 2010) 7.3 The Five Pillars of TPM 7.4 The Eight Pillars of Maintenance 7.5 Failure Mode and Effect Analysis 7.6 Root Cause Analysis 7.7 Fault Tree Analysis 7.8 Implementing a Solution  This lecture in a nutshell ⚫This lecture will basically … Introduce the concept of Total Productive Maintenance (TPM) Define the principles of TPM Define Failure Mode and Effect Analysis (FMEA) FMEA Categories Performing a service FMEA Define Root Cause Analysis (RCA) Process of RCA Techniques for RCA Implementing a Solution  Total Productive Maintenance (TPM) Slide 5 ⚫Total Productive Maintenance (TPM) TPM basically entails that doing maintenance tasks is not limited to the planned / unplanned activities of the maintenance crew. The entire workforce is involved, each in their own scope of activity operator 2 TPM relates to … operator1 Continuous activities (lubrication, cleaning, inspection, adjustments, housekeeping) maintenance crew Total quality improvement (good practice at all stages of a process) Empowerment of individuals by participation (engineers, operators) Principles of Industrial Maintenance Edith Cowan University 2018 Total Productive Maintenance (TPM) Slide 6 TPM strives to achieve … Increase equipment reliability Maximise uptime Improve quality and productivity Avoid breakdowns/unplanned downtimes 0 defects The above-goals can be achieved through (five TPM Pillars) …. 1. Planned maintenance 2. Maintenance free 3. Individual Kazen (continuous process improvement (CPI)) 4. Education and training 5. Self-maintenance Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 7 ⚫TPM Journey To plan and implement TPM, where should we start from? What steps should we consider? To run TPM, a clear plan/road map is required. Therefore, the following steps are required. Introducing TPM to employees Introducing goals and objectives of TPM Assessing current equipment conditions Assessing current maintenance effectiveness Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 8 ⚫Assessing current equipment conditions The equipment current conditions can be measured using the following indicators. Equipment reliability Frequency of failures Downtime percentage Backlog size Dedicated budget for maintenance This can be done by reviewing existing and past work orders, and equipment history. Each component of the equipment should be evaluated and ranked for the overall system condition. Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 9 ⚫Assessing current equipment conditions Rating Scale Condition Possible Actions Poor (1) Below all standards, Very difficult to operate, Requires immediate action: Unreliable, Very high OEE, Does not hold Scrap, rebuild, Start PM, Improve tolerance, No improvements done, Unsafe to function and safety, Clean up, operate, Very High scrap rate, No PM Repaint, Hide Fair (2) Barely acceptable, Below standards, Not easy to Requires early action: operate, Limited capability, Dirty, high OEE, High Rebuild, Improve function and safety, scrap rate, Very little PM Improve PM, Clean up, Improve inspection Average (3) Meets requirements, Fairly reliable, PM done. Not Requires action: in good condition, Limited capability, Average OEE, Improve necessary functions, Improve Average scarp rate inspections, Improve PM, Clean up Good (4) Reliable machine, Nice appearance, Very little Possible actions: scrap, All PM done, Some improvements done, Fine tune PM, Keep inspecting good (low) OEE, Meet all standards equipment, Keep cleaning/lubricating Improve where possible, Don’t let deteriorate Excellent (5) Perfect condition, Looks brand new, Excellent Use as example: capabilities, No scrap, Equipment improved, No Show off to customers, Don’t let breakdowns, Perfect PM done, Excellent (very low) deteriorate, Maintain perfect PM OEE record, Keep perfectly clean Source: Table 6-1. Stephens, Matthew P. (2010) Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 10 ⚫Assessing current equipment conditions Overall equipment effectiveness (OEE) is a reliable approach to evaluate the current equipment conditions. OEE = Availability × Efficiency × Quality Availability (also know as equipment utilisation) Availability is the ratio of actual operation time to net available time. Efficiency Efficiency is the ratio of the production time to actual production time. Stoppages, unavailability of parts, minor adjustments affect efficiency. Quality Quality is t he ratio of acceptable parts to the total parts. Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 11 ⚫Assessing current maintenance effectiveness Maintenance Program Productivity The current maintenance effectiveness/productivity is obtained by the product of three maintenance rankings (the ranking can be estimated using Table 6-2, Stephens, 2010, pg 157) Productivity=Utilisation × Methods × Performance EXAMPLE Adapted from Stephens (2010, pg 156) Given Assuming that a maintenance department is rated at 65%, 50%, and 75% in utilisation, methods, and performance, respectively. Task Calculate the organisation’s maintenance effectiveness. Productivity=0.65×0.5×0.75=0.24 or 24% Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 12 ⚫Implementing TPM To build and implement TPM, eight pillars/factors are required to be considered: 1. Support and guidance for operator self- maintenance activities What factors 2. Plan maintenance activities (prioritise should we consider productivity, safety, and cost) for implementing 3. Set up lubrication program TPM? 4. Manage spare parts inventory 5. Establish maintenance cost management system 6. Improve maintenance efficiency 7. Educate and train all operators 8. Reduce Reduce breakdowns breakdowns Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 13 ⚫Implementing TPM Failure Mode and Effect Analysis (FMEA) Source: news.gminternational.com/risk-analysis-fmea-failure-mode-effect-analysis Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 14 ⚫Implementing TPM Failure Mode and Effect Analysis (FMEA) FMEA: “The purpose of FMEA is to identify potential failures, that is, all the ways in which equipment, a process, or a product can fail; to determine how these failures can affect the overall operation of the equipment or the entire system; and to propose solutions or a course of action to eliminate these potential failures. (Stephens, 2010, pg 180) FMEA is grouped into four main categories: Design (potential failure modes due to engineering design mistakes) Process (potential failure modes due to operational mistakes) Application (potential failure modes associated with the use of end product) Service (potential failure modes due to service/maintenance mistakes) Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 15 ⚫Implementing TPM Performing a Service FMEA Service Potential Potential Potential O S D R Recommended Action failure effects of causes of C E E P actions take & mode failure failure C V T N date Source: Figure 7-1. Stephens, Matthew P. (2010) Service: Brief description of the service/maintenance task. Potential failure mode: Clear and concise statement of potential failure(s) for the stated service. Potential effects of failure: Statement of the consequences of each failure. Potential causes of failure: Statement of the identified root causes of the failure. Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 16 ⚫Implementing TPM Performing a Service FMEA Occurrence (OCC): Provides information (numerical ranking) about the expected frequency of each failure. Severity (SEV): Provides information (numerical ranking) about the effects and criticality of each failure. Detection (DET): Provides information (numerical ranking) about the likelihood of determining a failure. Risk Priority Number (RPN): This is calculated by multiplying the previous rankings. The value is used to prioritize the potential failures. Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 17 ⚫Implementing TPM Performing a Service FMEA Recommended action(s): Provides recommendation(s)/action(s) to reduce or completely eliminate potential failures and consequences. Action taken: Provides follow-up information to ensure recommended actions were taken to eliminate/reduce potential failures. The date of action needs to be recorded. Detected Failure with FMEA Failures Detected Failure without FMEA Time Principles of Industrial Maintenance Edith Cowan University 2018  Quiz Slide 18 ⚫ What are the main steps of FMEA process? Preparation Step 1: Create a team of experts Step 2: Identify scope and review the process, design, product, or service Step 3: Identify potential failure modes Identification Step 4: Identify potential effects of failure Step 5: Identify failure causes Step 6: Evaluate current conditions Prioritisation Step 7: Calculate RPN for each failure and prioritise failure modes Risk reduction Step 8: Provide recommendations Step 9: Take actions to reduce or eliminate potential failures Reassessment Step 10: Reassess risks with another FMEA Principles of Industrial Maintenance Edith Cowan University 2018 Total Productive Maintenance (TPM) Slide 19 ⚫Implementing TPM Root Cause Analysis (RCA) RCA objective is problem solving not problem generating. RCA technique should match the problem and helps to clarify the problem. RCA Techniques The common sense approach relies on common sense and experience pool of collected data is analysed. Change analysis assumes changes in various factors such as material, Process, etc. differences and changes to the equipment condition is analysed. Events and causal factors analysis uses an event and casual factors or Ishikawa diagrams to identify relationships Fault tree analysis Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 20 ⚫Implementing TPM Root Cause Analysis (RCA) The below table represents a sample form for change analysis. Processes Variables Conditions prior to failure Conditions after failure Variance Analysis Equipment: Feed Speed Etc. Materials: Type Specs Etc. Operator: Training Experience Etc. Environment: Temperature Humidity Etc. Other possible variables Source: Figure 7-7. Stephens, Matthew P. (2010) Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 21 ⚫Implementing TPM Root Cause Analysis (RCA) The below figure shows an event and casual factors diagram Event I Event II Conditions leading to each event Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 22 ⚫Implementing TPM Root Cause Analysis (RCA) The below figure shows an Ishikawa diagram The diagram is also known as fishbone or cause- and-effect diagrams Causes are generally referred to the six ‘Ms’: Material, Machine, Measurement, Methods, Manpower, Mother Nature. Cause Cause Contributing factors Contributing factors Contributing factors Problem (Effect) Contributing factors Cause Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 23 ⚫Implementing TPM Root Cause Analysis (RCA) The below figures show fault tree analysis diagrams This graphical display is used for complex relationships. Car will not Car will not start stop OR AND Starter malfunction Main brake fails Weather too cold Emergency break fails Principles of Industrial Maintenance Edith Cowan University 2018  Total Productive Maintenance (TPM) Slide 24 ⚫ Implementing a solution Regardless of the RCA methods used to identify root causes, the main aim is to find a solution. The solutions may be: Long-term (preferable) solutions require time and resources may require additional source of energy Short-term or temporary solutions time and resources are not available. Alternative solutions should be evaluated from implementation, cost, return on investment (ROI), technical feasibility perspectives. Different evaluation techniques are: Experimental study/laboratory tests Advanced software programs for simulation Mathematical and statistical tools Principles of Industrial Maintenance Edith Cowan University 2018 Quiz Slide 25 ⚫ Which of the following item(s) is correct? RCA … o may identify many root causes; however, only one or few of them have feasible solutions. o may be applied in either reactive or proactive situations. o is required to be applied for strong candidates, which have low RPNs. o requires operator experience and intuition in determining root causes. o long-term solutions are not preferred as they require time and resources. Principles of Industrial Maintenance Edith Cowan University 2018 Component Life Time Slide 26 Thank you Principles of Industrial Maintenance Edith Cowan University 2018