Planned Maintenance; a key pillar in world-class manufacturing

Maximizing Plant Performance with World Class Planned Maintenance

In the manufacturing environment, one timeless adage stands out: "To plan is to choose." This choice becomes particularly crucial when it comes to the maintenance of equipment and machinery, which are the lifeblood of any production facility. In the quest for zero breakdowns, increased reliability, and reduced maintenance costs, the Planned Maintenance (PM) pillar emerges as a beacon of hope. This proactive maintenance approach is executed on a predetermined schedule, with the goal of not only averting breakdowns but also optimizing the efficiency of maintenance operations.

The Power of Planned Maintenance

Imagine a scenario where maintenance activities are strategically planned and executed. This vision becomes a reality with the PM pillar. It brings about a dramatic transformation by boosting work productivity, freeing up the workforce, and creating room for more value-added activities. In fact, PM activities typically require only two-thirds of the labor needed for similar unplanned maintenance tasks. This efficiency is achieved by coordinating specialized maintenance skillsets, creating synergy, and driving plant performance to new heights.

However, building a robust PM pillar is not a standalone endeavor. It hinges on the foundational elements of the World Class Manufacturing (WCM) structure, including 6S, group activities, and visual management. Additionally, it draws strength from the Autonomous Maintenance (AM) pillar. PM encompasses both short-term and long-term activities. The former involves daily tasks carried out within the framework of 6S and autonomous maintenance activities. These efforts focus on reducing the irregularity of equipment failures. On the other hand, long-term activities entail monitoring, inspection, analysis, planning, and scheduling, ensuring the sustained performance of equipment.

The Crucial Role of Group Activities

To establish a robust PM pillar, the active involvement of the maintenance department in group activities is paramount. While AM and 6S group activities maintain the fundamental conditions of equipment, PM group activities dive deeper into eliminating breakdown sources and ensuring long-term performance. This collaborative approach ensures that the entire team works in tandem to achieve maintenance excellence.

Visual Management: The Key to Success

In the era of data-driven decision-making, visual management systems become instrumental in the success of the PM pillar. These systems provide a platform for transforming data into actionable information. Visual management helps in coordinating, monitoring, and initiating feedback on planned maintenance activities.

Work orders, generated by equipment and components, are executed by the maintenance team in a structured manner. This process consists of three essential steps: equipment/component analysis, work order generation, and quality checks on repaired or replaced components before they are released to the client. Visual management plays a dual role here, monitoring progress on equipment/components and overseeing work order execution. This transparency reveals progress, identifies bottlenecks, and addresses impediments to work order execution, ensuring a seamless maintenance workflow.

Reactive vs. Preventive vs. Predictive Maintenance

Understanding different maintenance approaches is crucial to appreciating the significance of PM. Reactive maintenance, the oldest approach, is known for repairing equipment only after a breakdown occurs. While suitable for low-cost, non-critical equipment, it results in unplanned downtime, increased energy costs, and risks associated with repeat jobs.

Preventive maintenance, carried out on a time or run-based schedule, aims to detect and mitigate equipment breakdowns. It offers cost savings through reduced failures, energy conservation, and maintenance flexibility. However, it is labor-intensive and does not eliminate the risk of catastrophic failure.

Predictive maintenance, also known as condition-based maintenance, relies on measurements to detect system weaknesses before significant deterioration occurs. It enables preemptive corrective actions, reduces spare inventory and labor costs, and improves product quality. However, it requires investments in diagnostic equipment and staff training.

Building the Pillar of Planned Maintenance

To successfully erect the PM pillar, several preconditions must be met. These include:

1. Developing a master equipment list for all equipment in the facility.

2. Prioritizing components based on importance and criticality.

3. Grouping components logically.

4. Defining maintenance activities and schedules.

5. Assessing maintenance staff and workload.

6. Allocating tasks to operations and maintenance groups.

7. Analyzing equipment failure modes and their impact.

8. Identifying maintenance tasks and mitigation actions.

The Four Phases of Planned Maintenance

The implementation of the PM pillar unfolds in four phases, each with a unique focus:

1. Reduction of Irregularity: This phase involves restoring equipment's basic conditions through 6S and the AM pillar. It reduces the minimum time needed for repairs and involves three steps: equipment analysis, improving the current state, and creating standards.

2. Extension of Equipment's Life Cycle: The second phase concentrates on enhancing equipment's lifespan by addressing weaknesses, preventing improper operations, and rectifying external deteriorations. This extension prolongs the time between failures.

3. Time-Based Restoration: Phase three is about restoring deteriorated parts to their original state through predictive measures, routine inspections, and improved diagnostics. It also enhances maintainability and detects abnormalities.

4. Prediction of Operating Life: The final phase anticipates the equipment's operating life, employing overall equipment diagnostics and pushing the equipment to its limits. This comprehensive approach blends various maintenance strategies to optimize plant performance.

Planned Maintenance (PM) isn't just another maintenance approach; it's a strategic choice that empowers manufacturing facilities to operate at their best. By coordinating efforts, implementing visual management systems, and transitioning from reactive to proactive maintenance, organizations can maximize their equipment reliability, reduce costs, and achieve world-class manufacturing status. With the right foundation and a commitment to excellence, the PM pillar becomes the cornerstone of success in the manufacturing world.