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By Rolly Angeles
First, of all I would like to dedicate this newsletter to all my maintenance brothers in India, as well as International Business Conference for choosing me to conduct this training on Reliability-Centred Maintenance. TPM or Total Productive Maintenance had already made it’s mark in India where a lot of industries are implementing its philosophy and principles. There are quite a lists of industries that are certified by JIPM (Japan Institute of Plant Maintenance), where a TPM Award ( 5 different types of awards to be exact) is achieved by quite a number of industries who have matured and reaped the rewards and benefits of their TPM implementation in their plant. I also noted that they have their own TPM Club India which I believe is a joint venture from JIPM which promotes TPM and provides references, consultation, seminars, conferences and research among TPM Industries as well as strengthen its ties with industries implementing TPM. In fact TPM have a very strong foundation in India and it have helped many industries achieved a level of achieving a World Class Environment on how they do business.
TPM is strongly recommended for manufacturing industries, yet even some oil and gas industries in India are implementing TPM. I am bit a little bit curious on how they compute their OEE or Overall Equipment Effectiveness if they are to consider the Quality Rate Component.
Reliability-Centred Maintenance is a new concept in India, while some may have heard of it yet others hardly knew what it’s all about. It’s concept and origin started from the airline industries and have a very strong foundation in the western part of the world. It is a strategy that highlights on achieving Reliability by focusing on Maintenance and its original standard SAE JA1011 will answer the 7 Basic questions as follows :
• What are the functions and associated performance standards of the asset in its present operating context ? • In what ways does it fail to fulfill its functions ? • What causes each functional failure ? • What happens when each failure occurs ? • In what ways does each failure matters ? • What can be done to predict or prevent each failure ? • What should be done if a suitable proactive tasks cannot be found ?
There are a lot of comparison as well as a lot of distinction between these two powerful concepts, in fact, I have layed down some of their strengths in my June 2008 Issue of Reliability Newsletter : Comparing RCM and TPM, which is the better strategy. http://www.rsareliability.com/newsletterjune2008issue.htm
I have spend around 8 years of my life implementing TPM as a senior TPM Engineer so I guess I have to say that TPM will always have a place in my heart and mind. So the question to raise is, can they fit together or will they blend together or not ?
To answer this question is to understand how both are taken up into as a focal point of strategy. If a plant is already having a strong TPM foundation, then RCM can fit into the system which I will explain but if a plant without TPM would want to initiate RCM, then for it to provide good results, both operations and maintenance should address the basic equipment condition first, a good lubrication, a clean equipment and an equipment with complete bolts.
TPM is for everyone in the organization while RCM is not design for each and everyone, in fact only those people from operations and maintenance with extensive knowledge of the asset they are operating should be part of the RCM team. If we speak about the military, these are elite forces like Delta Force or Special Ops.
TPM will always be the bigger program and RCM will be part of the Planned Maintenance pillar of TPM, yet if RCM is implemented with TPM, other TPM pillars would benefit from it such as Environmental, Health and Safety, Autonomous Maintenance, Focused Improvement for RCM decisions that will default to “REDESIGN or MODIFICATIONS”, Initial Flow Control Activities or Early Equipment Management, but the biggest impact of RCM in the TPM Pillar will be in the Planned Maintenance.
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How TPM’s Planned Maintenance Pillar is Implemented:
There is a wide range on how to effectively apply the Planned Maintenance system, just to give you a glimpse on how TPM’s Planned Maintenance pillar is applied in industries worldwide.
Reference : TPM Industries by Tokutaro Suzuki • Step 1 : Evaluate equipment and understand current conditions • Step 2 : Restore deterioration and correct design weaknesses • Step 3 : Build an information management system • Step 4 : Build a periodic maintenance system • Step 5 : Build a predictive maintenance system • Step 6 : Evaluate the planned maintenance system
Reference : Nissan Motor Co., Ltd, Yokohama Plant by : Yuichi Suzuki taken from TPM World Congress C4-2-8 • Phase 0 : Establishment of aims of planned maintenance • Phase 1 : Understanding of actual conditions of equipment and work • Phase 2 : Restoration of deterioration • Phase 3 : Recurrence prevention and countermeasure for weak points in design • Phase 4 : Establishment of periodic maintenance • Phase 5 : Improvement of maintenance efficiency • Phase 6 : Horizontal application • Phase 7 : Condition management of facilities
Reference : Idemetsu Kosan Co,. Ltd. Hokkaido Refinery by : Akira Kitayamna • Phase 1 : Deterioration, repair / elimination of forced deterioration • Phase 2 : Extension of characteristic life span • Phase 3 : Identify and repairing internal deterioration • Phase 4 : Pursue predictive maintenance and forecasting techniques
Reference : JIPM TPM Instructor’s Course Second Revision March 1996 • Phase 1 : The dispersion of reduced or extended MTBF (Mean Time Between Failure) - Restoration of unattended deterioration - Removal of forced deterioration and establishing key operating conditions • Phase 2 : Life span should be extended - Extend life expectancy and removal of sporadic failures • Phase 3 : Time-Based restoration of deteriorated portion to its original state - Assume lifespan and time-based restoration extend life expectancy - Understand irregularity for internal deterioration through the five senses • Phase 4 : Prediction of failure by the equipment diagnostic techniques - Failure mode for diagnosis and extension of lifespan by technical analysis of catastrophic Failures and breakdowns
Reference : As per my previous employment and JIPM Consultant • Step 0 : Preparatory stage and understanding the need of Planned Maintenance System • Step 1 : Perform initial cleaning • Step 2 : Restore deteriorations uncovered • Step 3 : Preparation of standard documents • Step 4 : Countermeasure for weak points In design • Step 5 : Periodic – Preventive Maintenance • Step 6 : Overall audit and diagnosis • Step 7 : Machine ultimate utilization
There are many versions on how TPM’s Planned Maintenance Pillar is implemented and may vary from one industry to another, yet whatever Phases or Steps is being adopted to comply with the consultants or TPM reference, they will end up in doing the 4 basic activities which are as follows : RCM will fit perfectly in the higher Phases of Planned Maintenance
Phase 1 : Establishing basic equipment condition through restoration Phase 2 : Address design weaknesses through improvement Phase 3 : Periodically restore deterioration w/ a Maintenance Algorithm or Decision Diagram Phase 4 : Achieve a Predictive Maintenance stage
Phase 1 : Establishing Basic Equipment Condition through Restoration Both Autonomous Maintenance and Planned Maintenance begin to accept the concept that their equipment is always a shared responsibility for both of them. These TPM pillars address abnormalities and perform restoration on their equipment. As Autonomous Maintenance address mostly the exterior part of the equipment, the Planned Maintenance pillar address the interior parts of their equipment. The goal of establishing Basic Equipment Condition in their equipment is to transition from a stage where Accelerated Deterioration is rampant to a stage of Natural Deterioration for parts which are Age-Related in nature. The objective of this Phase on Planned Maintenance is to reduce the amount of unplanned downtime caused by machine related problems mostly equipment breakdowns. Hence, when we perform Phase 1, we are dramatically improving our equipment in terms of reduction in unplanned breakdowns.
Phase 2 : Address design weaknesses through improvement Once accelerated deterioration had been reduced, equipments will suffer from natural deterioration. There are spares and parts of equipment that will deteriorate naturally. Team exposed themselves to study several parts of equipment with inherent short natural lifespan and correct design weaknesses by improving the parts dimension, strength of materials, construction, dimensions and so on. An MP (Maintenance Prevention) is usually used for this activity and later on feedback to the IFCA (Initial Flow Control Activity Group) or Early Equipment Management so that when the company decides to purchase future equipments these improvements are discussed with the designers to be included in the new equipment purchase. A cycle must be established where MP Design improvements must be feedback to IFCA. Correcting design weaknesses can prevent major breakdowns from recurring unexpectedly. Teams are trained on special tools such as P-M Analysis for a more detailed approach in dealing with Chronic Breakdowns. Likewise most breakdowns are caused by human errors, hence, both operators and maintenance must upgrade their skills to eliminate human errors, application of Poka-Yoke solution may solve human errors but not necessarily improve the level of understanding of the mistake caused by the person involved. Again for Phase 2, we are improving our equipment by addressing parts with design weaknesses.
Phase 3 : Periodically restore deterioration with a decision diagram Once the parts with design weakness had been addressed, its lifespan will change, hence, we need to have a thorough review on how we are going to maintain it. This is accomplished with the aid of a maintenance algorithm, RCM refers this as the decision diagram. A thorough study of the maintenance tasks must be done to establish the correct maintenance. Since the basics had already been established, we can performed this phase through Reliability-Centred Maintenance. Not all parts need to belong to the Time-Based system. This can be done by having a thorough understanding on how to maintain our equipment and activities to be performed. Each part have their own failure characteristic pattern. The key in this activity is to understand the 6 failure pattern so we can derive the correct maintenance tasks for each function through an Algorithm or Decision Diagram. In this activity we are not dealing with the equipment but rather on the system on how it is being maintained.. What parts must undergo time-based, what parts can be predicted, what parts needs inspection and what parts does not have any consequences at all and can be left to a No Scheduled Maintenance. In this Phase we are no long improving the equipment but rather the system on how the equipment is being maintained.
Phase 4 : Predict Equipment Life In Phase 4 we introduce the concept of Predictive Maintenance or Condition Based Monitoring Techniques, although this is similar in using the human senses in a much higher perspective with the aid of instruments. Several parts of equipment can be predicted through the use of these specialized equipment techniques. This is done by checking the condition of the equipment. The key on using this technique is to determine the P-F Interval, if a part shows symptoms then these parts are a good candidate for using Predictive Maintenance. For example, a bearing may produce noise, increase in temperature, increase in vibration or heat, these are symptoms or potential failure indicating that a failure is likely to occur or is in the verge of occurring. Therefore, maintenance can schedule the equipment. Advantage of using Predictive Maintenance is we can maximized the utilization of these part.
To conclude, these two powerful strategies are not meant to contradict one another but rather , they complement each other regardless of the their origin. No strategy is a silver bullet solution for every single problem we face in our plant. Perhaps an independent consultant on RCM with little background or knowledge on TPM will be biased as to which strategy to implement and vice versa, both strategies have their limitations as well as their strengths. I think I am one of the lucky once who know these two strategies by heart and mind. So my advise is before establishing any RCM efforts in your plant, try to address the basics first since by addressing the basics, some of these failure modes can be addressed.
I would like to thank all my reliability and maintenance brothers in India who have participated in my training as well as for my few lists of subscribers and hope that the concept of Reliability-Centred Maintenance may find its way in your industry which you can benefit from. I am very thankful and flattered by your feedback and responses as well as the hospitality and kindness of your people. Your feedback touched my heart.
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RCM and TPM are not meant to conflict one another but rather they complement each other. When use together they will provide a powerful tool in improving the way we maintain our equipment. Do the basics first which is TPM and once the basic equipment condition had been well established then let us address how to maintain our asset which is RCM. |
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RELIABILITY NEWSLETTER |
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Issue No. 17 - September 2008 |
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Since establishing this website last May of 2007, I have made many efforts to improve this site and provide some useful insights about our common link which is all about improving our equipment reliability and the way we do maintenance.
Finally should you be interested to contribute to our articles section or share any feedback, I encourage you to email me at rollyangeles@rsareliability.com. If for any reason you wish to unsubscribe from our newsletter, kindly send my a blank email with unsubscribe as the heading and we shall remove you from our mailing lists. Once again welcome to our September 2008 edition of our Monthly Reliability Newsletter for this year 2008 and I hope that you enjoy reading.
My Warm Regards,
Website : www.rsareliaiblity.com Email : rollyangeles@rsareliability.com |
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