Planned maintenance
Requires 100000 POINTS in the General category.PM Step1: Assess the machine and understand the current situation
Requires 100000 POINTS in the General category.PM Step2: Restore deteriorated conditions and improve weak points
Requires 100000 POINTS in the General category.PM Step3: Use breakdown analysis to identify breakdown's root cause
Requires 100000 POINTS in the General category.PM Step4: Build a periodic maintenance system
Step4: Build a periodic maintenance system
Repetitive breakdown-PM analysis.
Sporadic or new breakdown-Reliability centred maintenance (RCM) including X matrix and FMEA etc.
PM Step5: Build a predictive maintenance system
Step5: Build a predictive maintenance system
Use 5 sensory to predict malfunction.
PM Step6: Assess planned maintenance system
Step6: Assess planned maintenance system
>Maintenance cost: Direct maintenance cost, production loss by failure and financial management cost.
>4 M root cause analysis. Plant performance improvement.
Planned maintenance-overview
Planned maintenance Pillar:
>Increase plant performance;
>Reduce maintenance costs by up to 30%;
by:
>eliminating unplanned stoppages;
>developing a cost effective planned maintenance system through
- the involvement of line crew operators;
- enhancement of competencies and the implementation of systems in professional maintenance organization.
All this can be achieved with a four phases program, organised into 6 steps, implemented in three years.
Plant perfomance includes: OEE, breakdown,storage cost of spare parts,energy consumption,total maintenance cost.
PM eliminates unplanned stoppages, and most breakdowns are caused by simple reason that a good maintenance system can remove and handle.
PM requires the involvement of line crew operators to keep the equipment in control.
PM enhances competencies and implemens system in the maintenance organization.
Example of PM vision:
Study and implement an ideal maintenance policy by systematic improvement and cost effective maintenance activities of machine conditions.
Planned Maintenance: Vision/Mission example:
Pillar mission versus plant mission:
Pillar mission: To guarantee our internal customers' satisfaction
Strategy: To integrate maintenance team with operators through Autonomous Maintenance.
Link with Plant vision:Productivity and reliability.
Target of Planned maintenance pillar
Mission of PM (Planned maintenance)
To guarantee our internal customers satisfaction, Improving the Maintenance indicators through breakdowns and costs reduction.
Pillar indicators and result
General Yearly plan (For Year 2008)