This presentation explains preventive and Autonomous Maintenance techniques in a simple manner with numerous "Before & After" pictures. There are also formats available at the end of the presentation on the MIS reports and analysis to be done in the Maintenance function. This presentation is in Tamil Language. Please visit www.businessense.in to download this document.

1. MAINTENANCE
MODULE
IN TAMIL
An initiative of Hash Management Services LLP
A Business Sense Publication
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Introduction to Maintenance Function
 Maintenance function என்பது அனைத்து machines and equipments சரியாக
வேனல 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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Introduction to Maintenance function
கீழ் ேருேை Maintenance Functionன் முக்கியமாை சபாறுப்புகள் ஆகும்
 Machineஐ Basic conditionல் னேத்து இருப்பது
 Machineகனள Higher Levels of Performanceக்கு எடுத்து சசல்ேது
 Zero Failures , Zero Defects & Zero Accidents ஆக சசயல்படுேது
 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 இனடசேளியில்சசய்யப்படுேது - to keep
the machineஐ working conditionல் னேத்ைிருப்பைற்கு
 Autonomous Maintenance (AM) is a part of Preventive Maintenance (PM)
 AM என்பது machine Operatorவர சசய்ய வேண்டிய வேனலகள் ஆகும்
 இேற்னற கனடபிடித்ைால், Break-downs of machines zero ஆகி ேிடும்
Maintenance
Preventive
Maintenance
Autonomous
Breakdown
Maintenance

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Break-down Maintenance
 ஑ரு machine break downஆைவுடன், அந்ை operator, production
supervisorரிடம் complaint சசய்து Maintenance teamஐ ேரனேப்பார்
 Maintenance team ேந்ைவுடன் machineஐ சரி பார்பர்
 நினறய companyகளில், Maintenance teamமுடன் Service Level Agreement
ஏற்படுத்ைியிருப்பார்கள் ( e.g. maintenance team personnel 30 நிமிடங்களில் machineஐ
அனடய வேண்டும் )

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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 ஒவ்சோரு
machineக்கும் ஑ருேனர சபாறுப்பாளராக நியமிக்க வேண்டும்

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Autonomous Maintenance (AM)
 Operatorகள் அேர்களாகவே சசய்ேைாகும்
 Cleaning / Lubrication / Re-tightening / Inspection வபான்றனே இைில் அடங்கும்
 சிறு spare change வபான்றனேயும் இைில் அடங்கும்

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AM சசய்யும் முனறகள்
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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Step 1 – Preparation / ையார் சசய்ைல்
Step 2 – Initial Cleaning & Inspection / சுத்ைம்
& Inspection சசய்ைல்

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Step 1- Preparation / ையார் சசய்ைல்
 ஒவ்சோரு machineைின் functionஐ அறியவும்
 ஒவ்சோரு machineைின் safety aspectகனள அறியவும்
 Operator களுக்கு machineகனள பற்றி எடுத்துக்கூறவும்
 ஒவ்சோரு Machine partsஐயும் Identify சசய்து அைன் சசயல்பாட்னடயும்,
பயன்கனளயும் அறியவும்
Knowing the machine & its
parts is the primary step

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Step 2- Cleaning and Inspection
 Machineஐ சுத்ைமாக துனடக்கவும்
 கீழ் ேருேைேற்னற கேைிக்கவும்:
 Abnormality
 Hard to Access area
 Source of Contamination & Localization
 Unsafe Conditions

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Machineஐ துனடப்பது
 Cleaning சசய்ேைற்கு முன், எல்லா 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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Identification of Abnormality
 Dust
 Dirt
 Leak
 Rust
 Loose
 Damage
 Deformed
 Bolts and nuts/ joints
 Lubrication
 Transmission
 Hydraulics
 Pneumatics – gas system
 Electrical
 Safety
 Non standard
 Vibration
 Noise
 Misalignment
 Shaking
 Worn out
 Missing
Abnormalities எங்கு கண்டுபிடிப்பது ?

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Step 3 – Elimination of abnormalities

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Abnormalities in Bolts and Nuts
 Missing
 Loose
 Shaking
 Non standard bolts / washers
 Rusted
 Corroded
 Damaged
 Excess / low length
 Paint on threads and head

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Abnormality - Missing Nut
Missing Nut Nut fixed
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Abnormality - Missing screw
Missing Screw Screw fixed
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Abnormality – different nut
Different Nuts Same type nuts
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Abnormality – Painted bolt
Bolt head painted!
Difficult to remove the bolt in future
Paint removed from the bolt head
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Abnormality – bend in the bolt
Bend in the bolt New bolt and nut fixed
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Abnormality – different size washers
Different washers used Washers fixed
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Abnormality – rust in the bolt thread
Rust in the bolt thread Rust removed
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Abnormalities in lubrication
 Lubrication System Not Working
 No Grease in Reservoir
 No Visibility
 No Oil in the Gear Box
 Lubrication Level Low /High
 Grease / oil - Leak
 Without Grease Nipple & Cap
 Reservoir Tank Open
 Excess Greasing
 Oil / Grease Dust Contamination
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Abnormality – No grease in the reservoir
No grease Grease filled
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Abnormality – grease level not visible
Grease level not visible Grease level visible
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Abnormality – excess grease
Excess grease Optimal grease
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Abnormalities in Transmission
 Slackness
 Tight
 Damaged
 Misalignment
 Noise
 Key way worn out
 Key shaking
 Pulley/ belt / gear / shaft
damaged
 Belt missing
 Tracking
 Eccentricity
 Play

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Abnormality - slackness
Slackness in belt Slackness removed
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Abnormality – cooling fan not available
Cooling fan – not available Cooling fan fixed
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Abnormality – chain guard not available
Chain guard – not available Chain Guard - fixed
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Abnormality – oil leakage
Oil Leakage from the machine Oil Leak fixed
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Abnormalities in Hydraulic System
 Oil level low / high
 Oil contaminated
 Tank open
 Oil pressure low / high
 Oil temperature high
 Jerks / vibration
 Line damage
 Line not routed properly
 Noisy pump
 Pressure gauge not working
 Oil leak

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Abnormality – gauge not working
Gauge damaged / not working Gauge repaired
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34. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
Abnormalities in Pneumatic System
 Air / gas leak
 Line damage
 Line not routed properly
 Sluggish cylinder movements
 FRL unit not fixed in order
 Filter not drained of moisture
 Lubricator level low / high
 Oil flow rate high

35. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
Abnormality – air leakage
Air leakage Leakage arrestedThese are sample pictures used solely for understanding of the concepts. Hash Management Services LLP do not claim ownership of the pictures

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Abnormality – Steam leakage
Steam leakage Steam Leakage arrested
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Abnormalities in Electrical System
 Loose connections
 Hanging wires
 Cable not routed properly
 Cable gland loose
 Motor generating noise
 Motor generating more
heat
 Exposed wires
 Panel inlet filter block
 Panel/junction box open
 Screws missing
 Dust/dirt
 Connections with open
wires

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Abnormality – cables not routed properly
Cables not routed properly Cables properly fixed
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Abnormality – loose cables in the ground
Cables on the ground Cables laid properly
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Abnormality – holes in the switch box
Holes in the
switch box
Holes fixed
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Abnormality – Earthing not done
Earthing not done Earthing done
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Step 4 – Check lists and Audit templates

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Template 1 – List of abnormalities
VALVES
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Template 2 – Check lists
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Template 3 – Audit plan
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Template 4 – Status of the abnormalities
Red Tag Status
0
20
40
60
80
Put 64 68 12 14 12 10 16 12 14
Removed 62 64 10 11 10 8 10 14 16
Dec'06 Jan'07
Feb'07
I
Feb'07
II
Feb'07
III
Feb'07
IV
Mar'07
I
Mar'07
II
Mar'07
III
Nos
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Template 5 - Break-down register
S.No Machine
Break-down
reason
Breakdown time Machine up time
Time taken for
repair
Spares changed Corrective Action Preventive Action
1 Turret lathe Belt cut 10.30 AM 2.30PM 4 hrs Belt Regular checking
Monthly Audits and
monitoring the life time of
the belt

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Step 5 – Visual Management

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Visual Management
 Bolt Alignment –alignment
markingகனள கேைிக்கவும்
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Visual Management
 Working rangeஐ
காட்டுேைற்காக உள்ள
Markingஐ கேைிக்கவும்
 Needle எப்சபாழுதும் red
marks’க்குள் ைான் இருக்க
வேண்டும்
 Calibration date stickerஐ
கேைிக்கவும்
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51. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
Visual Management
 Grease level ஐ
காண்பிப்பைற்காக உள்ள
markingsஐ கேைிக்கவும்
 Red, yellow and green levelகனள
கேைிக்கவும்
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Visual Management
 Motor HP, Motor RPM, Sprocket and Chain Detail வபான்றேற்றின் stickerகனள
கேைிக்கவும்
 Chain rotation direction and eye symbol for inspection area
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53. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
Visual Management
 Lever Open and Close
markingகனள கேைிக்கவும்
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54. Property of Hash Management Services LLP. Unauthorized copying, circulating, modifying and using it without the knowledge / approval of Hash Management Services LLP is prohibited.
Visual Management
 Pressure markings in the pipes
and the direction of flowஐ
கேைிக்கவும்
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A Business Sense Publication
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MAINTENANCE
MODULE
IN TAMIL