Planned Maintenance
This audit serves as requirement to ensure alignment to JIPM standards and also for progression in the TPM cluster.
PLANNED MAINTENANCE STEP 2
The purpose of this audit is to ensure the Step 2 requirements of Planned Maintenance are being fulfilled. The requirements have been cross referenced with the Japan Institute of Plant Maintenance excellence award criteria.
Rating Scale: major deviation or more = 0, minor deviation= 1, meet expectations =2, exceeding expectations = 3, superior=4
STEP 2 PM DOCUMENTATION
REQUIREMENT / SCORE / RESPONSIBLEPast breakdown history: Data is actively collected on all failures/breakdowns for the model area and has been collected over a period of time. Collected data is shown on equipment logs or breakdown sheets. / Planned Maintenance Pillar Head
Equipment ranking: A standard has been developed for evaluating and ranking equipment based on criteria, such as safety, quality, operability, maintainability, cost, etc. / Planned Maintenance Pillar Head
Breakdown occurrence list: Data is collected on failure numbers, frequencies, severities, MTBFs, MTTRs, maintenance costs, etc. / Planned Maintenance Pillar Head
Selected PM equipment: Equipment has been ranked according to the evaluation standard and equipment for planned maintenance has been chosen, based on the ranking, frequency of failures, MTBF, MTTR or maintenance costs. / Planned Maintenance Pillar Head
Why-why analysis: Evidence is available of why-why analyses on failures. / Planned Maintenance Pillar Head and team
Countermeasures: Improvements developed for reducing failures, using any of the five countermeasures: restoring basic conditions, keeping the operating conditions, restoring deterioration, improving weak design and preventing human errors. / Planned Maintenance Pillar Head and team
Forecasting: Forecasting problems as a countermeasure to failures, using MTTR, MTBF, TBM or CBM for selected PM equipment (show evidence). / Planned Maintenance Pillar Head and team
Goals for reducing breakdowns: Goals have been set for reducing breakdowns through planned maintenance, with targeted timing. / Planned Maintenance Pillar Head
Activity plan: A plan has been prepared for carrying out the activities to achieve the above goals. / Planned Maintenance Pillar Head
Evidence requirements must be sought for each point to ensure the documentation is in use and active.
STEP 2PMPRACTICE EVIDENCE
REQUIREMENT / SCORE / RESPONSIBLECleaning Exercise: Basic conditions of equipment are maintained through TICL exercise at line side – cleaning, lubrication, inspection and minor repairs. / Autonomous Maintenance Pillar Head
Knowledge Test 1 Pillar Heads or Shop Floor:What is the difference between planned maintenance and reactive maintenance? PM - maintenance conducted at planned or scheduled intervals. Reactive maintenance – inspection and periodic replacement is not performed. Equipment is run to failure / Planned Maintenance Pillar Head/Shop Floor
Preventing deterioration: Name a task that team members can perform to prevent/reverse deterioration. TICL – maintaining basic conditions of equipment; minor repairs; report failures accurately; tagging. / Shop Floor
Benefits of planned maintenance: Name a benefit of planned maintenance.Maintain the quality of the part; Increase production up time; Reduce cost of operations; Reduce amount of machinery required; Ensure equipment capability and reliability. / Planned Maintenance Pillar Head/Shop Floor
Tag Register with Tag Count tracked over time:Tags are tracked. Dates for the tagging register must be validated to ensure daily checks with comments. There is maintenance support of AM activities to maintain the basic condition of machines. / Red Tags – AM Pillar Head and White Tags – FI Pillar Head
MTBF and MTTR: Explain what MTBF and MTTR are (can be explained through the calculation).MTBF – Adding the totaloperating time and dividing by the number of failures, to give the average amount of machine up time, before a failure occurs. MTTR – Adding the total repair time and dividing by the number of failures, to give the average amount of repair time taken for the breakdown/failure. / Planned Maintenance Pillar Head
FOCUSSED IMPROVEMENT STEP 1-7
FOCUSSED IMPROVEMENT AUDIT
REQUIREMENT / SCORE / RESPONSIBLEKaizen A3 Summary Sheet:
-Kaizensfor improvements in MTTR and MTBF,
-Kaizens for improving maintainability and reliability of equipment,
-Kaizens focussing on the elimination of environment causing forced deterioration,
-Kaizens have been closed off showing some results to date of improvement. / Focussed Improvement Pillar Head
Stepped FI plan with a list of all projects:
A detailed list of projects, expected completion date, responsible parties. / Focussed Improvement Pillar Head
Visual Board Update: All projects presented onto the visual board and tracked as per the weekly meetings. Team structures. / Focussed Improvement Pillar Head
Training and Development Matrix: Who has been trained, what is their level of competence towards TPM? The matrix should follow a competency check. / Education and Training Pillar Head
STEERING COMMITTEE REQUIREMENTS
REQUIREMENT / SCORE / RESPONSIBLE
Declaration:A company communication stipulating the objectives and commitment to TPM. / Focussed Improvement Pillar Head
PM Team Structures: Officiated organograms outlining team structures for the PM pillars. / Focussed Improvement Pillar Head
KPI’s: All projects and trainingare required to have KPI’s linked to a master KPI allocation. These are then cross referenced with Kaizen events and PM activities. / Focussed Improvement Pillar Head
TOTAL SCORE :
PERCENTAGE :
RESULT :
COMMENTS
AUDITORS:
PILLAR HEADS
STEERING COMMITTEE TEAM:
TPM STEP 2 AUDIT / 1