1. The Essentials - Maintenance
HASH MANAGEMENT SERVICES LLP
CHENNAI
PH: 91766 13965
2. Overview
‘The Essentials’ series from Business Sense is an initiative to empower the students(freshers) and
professionals in performing more efficiently and effectively in the organization
This document is a part of the “Certified Manufacturing Professional” course offered by Business Sense
This course is aimed at bridging the gap between the institutions and the industry by providing the
fundamentals of manufacturing management which are not offered by any of our
institutions/curriculum
This course would immensely benefit students and professionals who are joining manufacturing
organizations
For more details, please visit www.businessense.in
At Business Sense, we help clients through consulting engagements focusing on improving their
Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools.
We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and Supply
Chain Re-engineering.
You can subscribe to our bi-weekly newsletter here.
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4. Introduction to Maintenance Function
Maintenance function என்பது அனைத்து machines and equipments சரியாக
வேனை சசய்ேனை ensure சசய்ைிட வேண்டும்
Maintenance function, spares மற்றும் consumablesஐ plan சசய்து ோங்க
நடேடிக்னக எடுக்க வேண்டும்
layout change சசய்யும் வபாது machines and equipmentsஐ நகர்த்துேைற்கும்,
wiring சசய்ேைற்கும், சேளியாட்களுடன் co-ordinate சசய்ோர்கள்
அனைத்து machinesகளும் breakdown ஆகாமல் பாதுகாக்க வேண்டும்
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5. Responsibilities of an Engineer in the
Maintenance Function
Machineஐ Basic conditionல் னேத்து இருப்பது
Machineகனள Higher Levels of Performanceக்கு எடுத்து சசல்ேது
Zero Failures , Zero Defects & Zero Accidents ஆக சசயல்படுேது
Analyzing and stocking the Vital, Essential and Desired spares through VED
Analysis
MIS report of Break-down register and Preventive Maintenance schedule
னேத்து இருப்பது
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6. Types of Maintenance
There are 2 basic types of maintenance
Break-down Maintenance –Machine break down ஆை பின் சசய்ேது
Preventive Maintenance –Machine break down ஆேைற்கு முன் சசய்ேது -
Maintenance team ஆல் சீராை இனடசேளியில் சசய்யப்படுேது -
machineஐ working conditionல் னேத்ைிருப்பைற்கு
Autonomous Maintenance (AM) is a part of Preventive Maintenance (PM)
AM என்பது machine Operatorவர சசய்ய வேண்டிய வேனைகள் ஆகும்
இேற்னை கனடபிடித்ைால், Break-downs of machines, zero ஆகி ேிடும்
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7. Break-down Maintenance
ஒரு machine break down ஆைவுடன், அந்ை operator, production
supervisor’ரிடம் complaint சசய்து Maintenance teamஐ ேரனேப்பார்
Maintenance team ேந்ைவுடன் machineஐ சரி பார்பர்
நினைய companyகளில், Maintenance team’முடன் Service Level Agreement
ஏற்படுத்ைியிருப்பார்கள் ( e.g. maintenance team personnel 30 நிமிடங்களில்
machineஐ அனடய வேண்டும் , etc…)
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8. Preventive Maintenance
இது maintenance teamஆல் சசய்யப்படும் schedule based maintenance
program ஆகும்
Daily / weekly / fortnightly / monthly / quarterly plan for all machines
A preventive Maintenance calendar அனைத்து machineகளுக்கும்
ையாரித்து ஓவ்சோரு machineக்கும் ஒருேனர சபாறுப்பாளராக
நியமிக்க வேண்டும்
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9. Autonomous Maintenance (AM)
Operatorகள் அேர்களாகவே சசய்ேைாகும்
Cleaning / Lubrication / Re-tightening / Inspection வபான்ைனே
இைில் அடங்கும்
சிறு spare change வபான்ைனேயும் இைில் அடங்கும்
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10. Steps for Implementing AM
1. Preparation / ையார் சசய்ைல்
2. Cleaning and Inspection / சுத்ைம் & Inspection சசய்ைல்
3. Eliminate Problem Sources and abnormalities
4. Cleaning, Lubrication, Re-tightening, Inspection – Checklists and Audits
5. Visual Management
Please note that this list covers only the basics. This is not the
exhaustive list of steps as prescribed by the TPM model
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11. Step 1- Preparation
ஓவ்சோரு machineைின் functionஐ அைியவும்
ஓவ்சோரு machineைின் safety aspectகனள அைியவும்
Operator களுக்கு machineகனள பற்ைி எடுத்துக்கூைவும்
ஓவ்சோரு Machine partsஐயும் Identify சசய்து அைன்
சசயல்பாட்னடயும், பயன்கனளயும் அைியவும்
Knowing the machine & its parts is the primary step
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12. Step 2- Cleaning and Inspection
Machineஐ சுத்ைமாக துனடக்கவும்
கீ ழ் ேருேைேற்னை கேைிக்கவும்:
Abnormality
Hard to Access area
Source of Contamination & Localization
Unsafe Conditions
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13. Step 2- Initial Cleaning of the Machine
Cleaning சசய்ேைற்கு முன், எல்ைா WIP materialகனளயும்
முழுைாக cover சசய்ய வேண்டும்
Cleaning tools:
Cotton Waste
Tool Box / Trolley
Wire Brushes
Ladder , Screw Driver
Emery Sheet - Medium
Cleaning Agent – Kerosene , Soap oil
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14. Step 2- Identification of Abnormality
எங்கு கண்டுபிடிப்பது ?
Abnormalities
Dust Non standard Bolts and nuts/ joints
Dirt Vibration Lubrication
Leak Noise Transmission
Rust
Misalignment Hydraulics
Loose
Shaking Pneumatics – gas system
Damage
Deformed Worn out Electrical
Missing Safety
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15. Step 3 – Elimination of abnormalities
Missing Nut Nut fixed
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16. Step 3 – Elimination of abnormalities
Different Nuts Same type nuts
Remaining steps with pictures and Report templates are explained in the “Certified Manufacturing
Professional” course. To access login to www.businessense.in
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17. End of Free Content
Please visit our website www.businessense.in to access the full course – “Certified Manufacturing
Professional”
Our website also contains list of ready-to-use templates and report formats containing Charts and
pivot tables.
Templates and report formats are available for Purchase, Stores, Production, Quality, Maintenance and
HR functions
These templates come in excel /word and can be downloaded and used right away
At Business Sense, we help clients through consulting engagements focusing on improving
their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and
other tools.
We also serve clients on Preparation of Detailed Project Reports, Market Assessments, and
Supply Chain Re-engineering.
You can subscribe to our bi-weekly newsletter here.
Follow us:
Copyright of Hash Management Services LLP www.businessense.in