KAIZEN TOOL FOR MANAGEMENT OF MAINTENANCE – ENGINEERING – PRODUCTION - HOP VIET TECH CO., LTD

KAIZEN TOOL FOR MANAGEMENT OF MAINTENANCE – ENGINEERING – PRODUCTION

HOW TO

👍Do maintenance machines – equipment (the important assets of the Manufacturing-OEM Maker Company which is also the Tools to make profits for Company and workers’ income) more efficient for machines running more stability, efficiency to increase productivity and more?

👍Make the company get more profitable and more competitive?

👍Make the employee get more income without sacrifice the Health and Time?

Do hope you can find out your 🔑 from this 10 FQAs– frequently questioned answers about “Kaizen Tool for Management Of Maintenance, Engineering and Production”

1. Q: WHAT IS MAINTENANCE?

A: MAINTENANCE is the act of maintaining, the state of being maintained, care or upkeep of machinery, the process of maintaining or preserving machine – equipment in good condition for industrial, business, governmental, and residential installations. 

Over time, this has come to include multiple wordings that describe various Cost-effective practices to keep equipment operational.

Often maintenance functions are referred to as Maintenance, repair and overhaul (MRO) and MRO is also used for Maintenance, repair and operationsOver time, the terminology of maintenance and MRO has begun to become standardized.

The maintenance and maintenance of equipment at the factory plays an extremely important role for the continuous operation of the factory. The most effective maintenance plan is usually based on the experience, manpower, equipment and maintenance available. To minimize downtime of the plant, all tasks such as inspection and maintenance preparation can be performed while the plant is operating.

Benefits of machine maintenance activities

– Increasing availability of machines – equipment.

– Reduce downtime.

– Reduce production costs.

– Improve productivity.

 

2. Q: WHAT TYPE OF MAINTENANCE STRATEGY?

A: THERE ARE FOUR MAINTENANCE STRATEGIES:

1. RUN TO FAILUREHAY BREAKDOWN MAINTENANCE

– Equipment is severely damaged or destroyed.

– Unplanned maintenance

– Loss of income from products due to machine outages

2. PREVENTIVE MAINTENANCE

– Better than Run To Failure

– Planning Stopped the machine

– There are still Unnecessary maintenance and damage due to improper maintenance

3. PREDICTIVE MAINTENANC

– Maximum lifespan by monitoring abnormal conditions and detecting errors

– Reducing unplanned machine downtime by alerting users about mechanical / electrical changes

– Optimizing operations

4. PROACTIVE MAINTENANCE

-Determine repeated damage

-Identify the root cause of damage

-Solve the root cause to eliminate future damage

DO YOU KNOW PREVENTION, PREDICTION AND PROACTIVE MAINTENANCE CAN

– INCREASE MORE 25% MACHINE PERFORMANCE

– SAVING 30% MAINTENANCE COST

– SAVING 45% UNPLANNED MACHINE DOWNTIME

SO CHOOSING THE MAINTENANCE STRATEGY COMPLIANCE WITH EACH MACHINERY AND EQUIPMENT OF THE FACTORY IS VERY IMPORTANT TO THE MAINTENANCE-TECHNICAL MANAGEMENT MANAGER, ALSO FOR THE DEVELOPMENT STRATEGY OF THE PRODUCTION COMPANY.

3. Q: WHAT IS TOTAL PRODUCTIVE MAINTENANCE (TPM)?

 A: Total Productive Maintenance (TPM) is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization.

TPM focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes.

Total Productive Maintenance (TPM) was developed by Seiichi Nakajima based on the experience of the practical application of maintenance best practices in Japan between 1950 and 1970. This experience led to the recognition that a leadership mindset engaging front line teams in small group improvement activity is an essential element of effective operation.

The goal of TPM is the continuous improvement of equipment effectiveness through engaging those that impact on it in small group improvement activities. Total quality management (TQM) and total productive maintenance (TPM) are considered as the key operational activities of the quality management system. In order for TPM to be effective, the full support of the total workforce is required. This should result in accomplishing the goal of TPM: “Enhance the volume of the production, employee morals, and job satisfaction.”

The main objective of TPM is to increase the Overall Equipment Effectiveness (OEE=Performance x Availability x Quality) of plant equipment.

TPM addresses the causes for accelerated deterioration while creating the correct environment between operators and equipment to create ownership.

Each factor has two associated losses making 6 in total, these 6 losses are as follows:

Performance = (1) running at reduced speed – (2) Minor Stops

Availability = (3) Breakdowns – (4) Product changeover

Quality = (5) Startup rejects – (6) Running rejects

The objective finally is to identify then prioritize and eliminate the causes of the losses. This is done by self-managing teams that solve problem. Employing consultants to create this culture is a common practice.

PRINCIPLES

The eight pillars of TPM are mostly focused on proactive and preventive techniques for improving equipment reliability:

        1. Autonomous Maintenance: The operator of the machine knows how to repair, maintain and identify the damage to a certain extent. Self-maintenance helps the operator know the structure and function of the machine, understands the relationship between the machine and the quality, is accustomed to strict compliance with regulations so that the detection and diagnosis of any abnormalities can be accurately diagnosed of the machine as well as the fastest and most appropriate way to fix it.     2. Focused Improvement: Priority is focused on improving key issues first. In addition, encourage small improvement initiatives of each individual or department.

     3. Planned Maintenance: to implement the motto “preventive rather than cure” to avoid stopping the machine, avoiding repetitive errors, increasing machine life, reducing repair time and maintenance costs.

     4. Quality management: build a good quality management system, quality control from the first stage to the stage of distribution and after-sales, with a system of remediation and prevention. At the same time, analyze the production process to find the errors easily and fix it.

     5. Early/equipment management: look at every stage of production from start to finish and look for ways to improve weaknesses from the beginning.

     6. Education and Training: without proper training and standardization, TPM and maintenance systems in general, would not be possible. The training must ensure quality and efficiency.

     7. Administrative & office TPM: Indirect production activities of TPM are very important … their mission is to collect, process, provide information, and serve other production needs.

     8. Safety Health Environmental conditions: progressing to no labor accidents, no occupational diseases, no adverse environmental impacts. Particular emphasis is placed on the safety of equipment operators.

With the help of these pillars, we can increase productivity. Manufacturing support.

  

IMPLEMENTATION

Following are the steps involved by the implementation of TPM in an organization:

1. Initial evaluation of TPM level,

2. Introductory Education and Propaganda (IEP) for TPM,

3. Formation of TPM committee,

4. Development of a master plan for TPM implementation,

5. Stage by stage training to the employees and stakeholders on all eight pillars of TPM,

6. Implementation preparation process,

7. Establishing the TPM policies and goals and development of a road map for TPM implementation.

According to Nicholas, the steering committee should consist of production managers, maintenance managers, and engineering managers. The committee should formulate TPM policies and strategies and give advice. This committee should be led by a top-level executive. Also a TPM program team must rise, this program team has oversight and coordination of implementation activities. As well, it’s lacking some crucial activities, like starting with partial implementation. Choose the first target area as a pilot area, this area will demonstrate the TPM concepts. Lessons learned from early target areas/the pilot area can be applied further in the implementation process.

SO “TPM IS A MAINTENANCE PROGRAM INCLUDING MANY NEW DEFINITIONS FOR EQUIPMENT MAINTENANCE” with the Program’s objectives and benefits being to increase production capacity, while increasing knowledge, skills and satisfaction for the labor. In the work of employees, increasing productivity, reduce waste products, Reduce wastage and waste, Reduce production and maintenance costs, Reduce storage, Reduce labor accidents, Increase profits for Enterprises.

TPM is focused on keeping all equipment in the best working condition to avoid problems and delays in production and business processes.

 

       4. Q: HOW TO ACHIEVE TPM’S MAIN TARGET IS “INCREASING OVERALL EQUIPMENT EFFECTIVENESS EQUIPMENT EFFECTIVENESS” (OEE = PERFORMANCE X AVAILABLE X QUALITY) “?

A: By implementation: The Eight Pillars of TPM with the most foscus on

     1. Autonomous Maintenance: The operator of the machine knows how to repair, maintain and identify the damage to a certain extent. Self-maintenance helps the operator know the structure and function of the machine, understands the relationship between the machine and the quality, is accustomed to strict compliance with regulations so that the detection and diagnosis of any abnormalities can be accurately diagnosed of the machine as well as the fastest and most appropriate way to fix it.

      2. Planned/Preventive Maintenance: to implement the motto “preventive rather than cure” to avoid stopping the machine, avoiding repetitive errors, increasing machine life, reducing repair time and maintenance costs.

         3.Focused Improvement: Priority is focused on improving key issues first. In addition, encourage small improvement initiatives of each individual or department.

    

AND IT SHOULD BE IMPLEMENTED SYNCHRONIZED BY EVERYONE IN THE COMPANY

5. Q: HOW TO IMPLEMENT 3 IMPORTANT FACTORS OF TPM

– Autonomous Maintenance

– Planned Maintenance

– Focus Improvement

A: ONLY BY FIDING OUT THE CAUSE OF MACHINE FAILURE LEAD TO LOST OF PERFORMANCE AND EFFICIENCY, AND IMPROVE FOR IT EVERY DAY AND STEP BY STEP.

WE CAN START FROM THE MACHINE WHICH GOT PROBLEMS (FAILURE, DAMAGE, UNWANTEDSTOP)

6. Q: SO WHERE SHOULD DO WE START?

A: WE COULD START FROM BEARING BECAUSE “BEARING” IS THE HEART OF THE MACHINE-EQUIPMENT, IT IS THE MAIN TRANSMISSION EQUPMENTS OF ALL INDUSTRIAL AND CIVIL APPLICATION”

AUTOMOTIVE BEARING (CAR TYRE TRASMISSION BEARING)

WIND TURBINE GENERATOR BEARING

And also because the majority of Machinery and equipment failure start from the failure of the “BEARING”

7. Q: WHAT IS “THE ROOT CAUSE OF BEARING FAILURE” ESPECIALLY WHEN THE INDUSTRY BEARING LIFE (L10 LIFE) IS FROM 20,000-200,000 WORKING HOURS (2.3-23 YEARS) AS PER BELOW FIG, BUT THERE ARE MANY FACTORY REPLACEMENT BEARING VERY OFTEN (EVERY YEAR OR LESS)?

A: There are many causes, And the main CAUSE OF BEARING FAILURE RELATED TO THE LUBRICATION (including too much-too less lubrication, and contamination), According to the below CHART OF SKF (THE WORLD’S LARGEST BEARING MANUFACTURER)

AND “LUBRICATION ALSO THE MAIN CAUSE OF MACHINE DAMAGE”

An easy example is: if we use improperly lubricant oil (like using Motorbike lubricant oil) for Cars, then make sure that a very short period of time, we will have to overhaul repair the Car’s Engine or sell off of the Car!

OF COURSE WE DO NOT NEED TO DO THAT MAKE FOR TESTING BECAUSE THERE ARE MANY RESEARCHS ON THE CAUSE AND COST OF MACHINE FAILURE IN THE WORLD AS FOLLOW CHART (43% COST OF MACHINE FAILURE COMING FROM THE LUBRICATION: INCLUDING WRONG LUBRICANT OF USING AND WRONG WAY OF FEEDING)

                 8. Q: IF “LUBRICANTION IS THE MAIN CAUSE OF MACHINE-EQUIPMENTS’ S DAMAGES “SO WE HAVE ALREADY PAY ATTENTION ENOUGH ON IT YET?

A: SORRY THAT THE ANSWER IS “NOT YET”: Especifically, you can see that LUBRICATION costs is only 1-3% of the total Maintenance cost, while LUBRICATION is 50% causes of bearing failure and 43% machine-equipments’ s damages.

There are many reasons for the above missing of attention on the main “Roots Cause”

                1. BECAUSE We may not pay attention for the “LUBRICATION OF MACHINE-EQUIPMENT”, and may think that lubrication is simply about feeding the lubricant for the machine… And so we may choose 1 type of grease using for all the machine-equipment of the Factory. And Over lubrication as below Fig is Very easy to find and quite common in many Plants.

 

*DO YOU KNOW “34% CAUSE OF BEARING FAILURE DUE TO INADEQUATE LUBRICATION , AND ALMOST IS OVER LUBRICATION  DUE TO THE MANUAL LUBRICATION.

AND OVER LUBRICATION CAN LEAD TO  INCREASE TEMPERATURE AND GREASE OXIDATION SPEED FASTER (IF THE TEMPERATURE RISER 10°C THEN THE GREASE OXIDATION BECOME FASTER 2 TIMES OR GREASE LIFE  IS REDUCED A HALF”

And BECAUSE We may not see the “Indirect Maintenance Cost” which almost come from “MACHINE FAILURE OR BEARING FAILURE OR LUBRICATION FAILURE”

               2. BECAUSE We do not know the above information or we have not been trained in Lubrication or Maintenance form the University or from the Company.

So We may not know or perceive “The Role and Meaning of Maintenance Job is “To ensure and maintain the machinery and equipment in good operating condition meaning maintenance the production efficiency, the operation and business of the Company running well”.

The Good Maintenance person is not the one who can fix the machine or fix the problem well, but the one who can control and prevent the problem as little as possible.

There was a European customer friend who was the Director of Maintenance & Technology for a Company in Vietnam once shared, “When I was a University Student I was trained as: A Good Maintenance man is the one who can keep the Machines busy instead of he is busy, because only when machines are busy working the it will create products, values, salaries for employees and profits for the Company.

                          3. BECAUSE We may know all of the above information, but we have no way to control and implement the lubrication effectively and properly?

                  9. Q: SO WHERE ARE THE SOLUTIONS TO CONTROL AND IMPROVE EFFICIENT OF LUBRICATION FOR THE COMPANY?

              A: TO ” TO CONTROL AND IMPROVE EFFICIENT OF LUBRICATION WE ONLY NEED TO MAKE 6 RIGHT THINGS AS FOLLOWING (6R).

        1. RIGHT LUBE MEAN EACH MACHINE AND EACH APPLICATION NEED EACH TYPE OF SUITABLE LUBRICANT, THAT’S WHY THERE ARE MANY TYPE OF LUBRICANTS.

2. RIGHT TIME: LUBRICANTION NEED TO CONTINUOUSLY  EVENLY.

         3. RIGHT QUANTITY (OPTIMAL LEVE, IT IS NOT TOO MUCH OR TOO LITTLE): I am not surprised that so many guys doing Maintenance and Engineering are still thinking that The Purpose of Machine Lubrication is “Replace old grease with new grease by injecting new grease into the Bearing until it fills up and overgreased!”

Because no school and no company training us about it.

Actually, I used to think the same as before, until I went into more depth and trained by the Company Partner to provide automatic lubrication solution …

In fact, the purpose of Lubrication is Lubrication suitable by “Always maintain a thin layer of grease-oil between moving parts when the machine is working”, because it will ensure the movement of the machine, and make it work smoothly, reducing speed of wear, damage, friction and vibration

Because if the lubrication is not appropriate, moving parts can rub in the absence of lubrication, causing overheating (when too much or too little lubrication) and destroying metal strength, resulting in damage to the parts. transmission mechanism, machine failure … “

(* According to the definition from Wikipedia).

 

The below Fig is the enlarged cut layer of the friction position when bearing working

MEDIUM-OPTIMAL LUBRICATION

OVER LUBRICATION (TOO MUCH GREASE)

UNDER LUBRICATION (TOO LESS GREASE)

4. RIGHT LOCATION

5. RIGHT WAY (DO NOT HAVE THE CONTAMINATION INTO LUBRICANTS AND LUBRICANT POINTS)

6. RIGHT CONDITIONS

10. Q: HOW CAN WE APPLY FOR 6R ABOVE?

A: like a lot of other technical problems, to improve the efficiency of lubrication “we simple apply the available technology available in the world” 

and “automatic lubrication” is one of the solutions that have been invented and applied widely in the world for more than 30 years because of many of it’s benefits compare to the manual lubrication.

Discover more about

Manual Vs Automatic Lubrication 

 https://hopviet.com.vn/2020/02/manual-lubrication-vs-automatic-lubrication/?lang=en

Automatic Lubrication Successful Application Case Study For Application Fields

https://hopviet.com.vn/category/application/?lang=en

SOURCES

https://www.maintworld.com/

Plant Engineering

https://www.plantengineering.com/

https://www.machinerylubrication.com/

 

LINK FOR DOWNLOADING DOCUMENT OF ABOVE CONTENT (SHORT VERSION)

https://drive.google.com/file/d/1Fn05s_AtMwbMbgQ9jdUduc0_Uj4LDv0G/view?usp=sharing

 

INDUSTRIAL AUTOMATIC LIBRICATION Q&A

CALIBRATION=MAINTAIN THE STANDARD-QUALITY-SAFETY

MANUAL LUBRICATION VS AUTOMATIC LUBRICATION

AUTOMATIC LUBRICATION FOR ELECTRIC MOTORS

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