{"id":6309,"date":"2017-08-10T08:51:21","date_gmt":"2017-08-10T08:51:21","guid":{"rendered":"https:\/\/www.ribcon.com\/?p=6309"},"modified":"2025-11-27T08:57:38","modified_gmt":"2025-11-27T08:57:38","slug":"tpm-understanding-step-1-3-of-planned-maintenance-pillar","status":"publish","type":"post","link":"https:\/\/www.ribcon.com\/tpm-understanding-step-1-3-of-planned-maintenance-pillar\/","title":{"rendered":"TPM Understanding Step 1-3 of Planned Maintenance Pillar"},"content":{"rendered":"<h2>TPM: Understanding Step 1-3 of Planned Maintenance Pillar<\/h2>\r\n<p><img loading=\"lazy\" decoding=\"async\" src=\"https:\/\/www.ribcon.com\/wp-content\/uploads\/2017\/08\/IMG_1853-768x574-1.jpg\" alt=\"\" width=\"768\" height=\"574\" class=\"alignright alignnone size-full wp-image-6312\" srcset=\"https:\/\/www.ribcon.com\/wp-content\/uploads\/2017\/08\/IMG_1853-768x574-1.jpg 768w, https:\/\/www.ribcon.com\/wp-content\/uploads\/2017\/08\/IMG_1853-768x574-1-300x224.jpg 300w\" sizes=\"auto, (max-width: 768px) 100vw, 768px\" \/><\/p>\r\n<p>Objective of Planned Maintenance pillar in TPM is to enhance natural life of the equipment by focuses on two key category of activities:<\/p>\r\n<ul>\r\n<li>Maintenance Activities to fix and prevent failures<\/li>\r\n<li>Improvement Activities\r\n<ul>\r\n<li>To extend life span of part,<\/li>\r\n<li>To shorten maintenance time<\/li>\r\n<li>To avoid maintenance<\/li>\r\n<\/ul>\r\n<\/li>\r\n<\/ul>\r\n<p><span><strong>Planned Maintenance has following 7 steps:<\/strong><\/span><\/p>\r\n<ul>\r\n<li>Support Autonomous Maintenance Teams<\/li>\r\n<li>Understand Equipment Failures<\/li>\r\n<li>Reverse Deterioration<\/li>\r\n<li>Build Information Management system<\/li>\r\n<li>Build Periodic Maintenance system<\/li>\r\n<li>Build Predictive Maintenance system<\/li>\r\n<li>Evaluate and improve<\/li>\r\n<\/ul>\r\n<p><strong><span>In Planned Maintenance step 1, maintenance team supports the Autonomous Maintenance<\/span><\/strong>activity by training operators to identify &amp; correct abnormalities on their machines. Following are roles of Maintenance team in Planned Maintenance step 1<\/p>\r\n<p><span><strong>Autonomous Maintenance Step 1:<\/strong><\/span><\/p>\r\n<ul>\r\n<li>To explain machine function and mechanical functions and define basic conditions \u2013 normal and abnormal<\/li>\r\n<li><span>Guidance for\u00a0<\/span>Identification of cleaning, inspection and lubrication items and Cleaning tools management<\/li>\r\n<li>Abnormality identification training \u2013 and teach about red\/white tags<\/li>\r\n<li>Teach how to develop One Point lessons<\/li>\r\n<li>Help to dis-cover difficult to access areas<\/li>\r\n<li>Inspection while cleaning \u2013teaching this to operators.<\/li>\r\n<li>Training the operators on moving parts, functional inspection of the rotating mechanisms, to find out abnormalities and making operators judge pass-fail criteria.<\/li>\r\n<\/ul>\r\n<p><span><strong>Autonomous Maintenance Step 2:<\/strong><\/span><\/p>\r\n<ul>\r\n<li>Assist and implement countermeasures for sources of contamination by fabricating<\/li>\r\n<li>carrying out trials, installing and improving guards etc. This will include activities such as:<\/li>\r\n<li>Make machine easy to clean, lubricate and tighten \u2013 by operator with their involvement.<\/li>\r\n<li>Conducting WHY-WHY analysis of breakdown and if the reason being lack of Autonomous Maintenance activities then fill the skill gap.<\/li>\r\n<li>Prepare localized guards &amp; Arrest leakages<\/li>\r\n<li>Removal of red\/pink tags \u2013 explain and do.<\/li>\r\n<li>Rectifying the major abnormalities, which cannot be done by operators.<\/li>\r\n<li>To train the operators for developing, with one point lessons.<\/li>\r\n<li>To train operators to conduct daily autonomous maintenance activities safely.<\/li>\r\n<li>Attend to suggestions made by operators in form of countermeasures by AM team that they couldn\u2019t implement themselves.<\/li>\r\n<\/ul>\r\n<p><span><strong>Autonomous Maintenance Step 3:<\/strong><\/span><\/p>\r\n<ul>\r\n<li>Preparation of visual control \u2013 to make the changes in equipment including auxiliary units so that they are easy to clean, access, inspect and lubricate.(Re-tighten) make the equipment \u2018visually controllable\u2019 by operators<\/li>\r\n<li>Decide frequency for Cleaning, lubricating, tightening, making the method to do it and decide who will do what. Then teach that person \u2018How\u2019 to do.<\/li>\r\n<li>Provide the right kind of tools near the machine for operator to use. Similarly provide appropriate tools to maintenance for their work<\/li>\r\n<li>Prepare Breakdown sheet on which all breakdowns will be recorded and analysed<\/li>\r\n<li>Correct abnormalities that are identified through inspection.<\/li>\r\n<li>Establish standards for lubrication and monitoring pressure\/temperatures<\/li>\r\n<li>Establish standards for cleaning<\/li>\r\n<\/ul>\r\n<p><span><strong>Planned Maintenance Step 2: Understanding Equipment failures.\u00a0<\/strong><\/span><\/p>\r\n<p>Following key activities are done in PM Step 2<\/p>\r\n<ul>\r\n<li>Collect data on all failures\/ breakdowns<\/li>\r\n<li>Prepare Equipment control ledger<\/li>\r\n<li>Do Equipment Ranking &amp; Select High Rank Equipment for PM activities<\/li>\r\n<li>Understand current conditions based on OEE, MTBF, MTTR, Maintenance Costs etc<\/li>\r\n<\/ul>\r\n<p><span><strong>Planned Maintenance Step 3 focuses on reversing deterioration by focusing on following key activities<\/strong><\/span><\/p>\r\n<ul>\r\n<li><span>Root Cause Analysis on breakdowns and Design improvements to reduce natural breakdown<\/span><\/li>\r\n<li><span>Develop Skill to forecast breakdowns, Develop countermeasures, Measure &amp; Monitor MTBF MTTR<\/span><\/li>\r\n<li>Implement and Follow Time based Maintenance and Condition based Maintenance systems<\/li>\r\n<\/ul>","protected":false},"excerpt":{"rendered":"TPM: Understanding Step 1-3 of Planned Maintenance Pillar Objective of Planned Maintenance pillar in TPM is to enhance natural life of the equipment by focuses on two key category of activities: Maintenance Activities to fix and prevent failures Improvement Activities To extend life span of part, To shorten maintenance time To avoid maintenance Planned Maintenance...","protected":false},"author":1,"featured_media":6310,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"inline_featured_image":false,"footnotes":""},"categories":[286],"tags":[],"class_list":["post-6309","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-tpm","related_industries-phenomenon-mechanism-analysis","related_industries-planned-maintenance","related_industries-root-cause-analysis","related_services-overall-equipment-effectiveness","related_services-tpm-audit","related_services-tpm-consulting"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v26.9 - 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