Planned maintenance

Requires 100000 POINTS in the General category.
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PM Step1: Assess the machine and understand the current situation

Requires 100000 POINTS in the General category.
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PM Step2: Restore deteriorated conditions and improve weak points

Requires 100000 POINTS in the General category.
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PM Step3: Use breakdown analysis to identify breakdown's root cause

Requires 100000 POINTS in the General category.
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PM Step4: Build a periodic maintenance system

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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

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Step5: Build a predictive maintenance system
Use 5 sensory to predict malfunction.

PM Step6: Assess planned maintenance system

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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

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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.

Most causes of failure

PM requires the involvement of line crew operators to keep the equipment in control.

Involvement of line crew operators

PM enhances competencies and implemens system in the maintenance organization.

PM vision and mission

Example of PM vision:

Study and implement an ideal maintenance policy by systematic improvement and cost effective maintenance activities of machine conditions.

PM VISION example

Planned Maintenance: Vision/Mission example:

PM vision and 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.

Maintenance map interaction of AM and PM

 

Target of Planned maintenance pillar

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 Mission of PM (Planned maintenance)

 To guarantee our internal customers satisfaction, Improving the Maintenance indicators through breakdowns and costs reduction.

 Pillar indicators and result

Pillar indicators and result

General Yearly plan (For Year 2008)

Expand RCM to A、B machine to improve TBM (Time based maintenance) system;
 
Explore more CBM (condition based maintenance) activities (with Thermo-Graphic inspection and vibration monitoring);
 
Reduce maintenance cost; (from 100% of Y2005 to 95%);
 
Continue to support AM.
 
Focus on staff training (review maintenance skill matrix, arrange training plan).