Planned M Aintenance: Gearing Towards A Pro-Active Maintenance System

Planned M aintenance
Gearing Towards A Pro-Active Maintenance System
Table of Contents
1 Introduction on Planned Maintenance
1.1
1.2
1.3
1.4
1.5
1.6
1.7
Understanding the Need For A Planned Maintenance System

Planned Maintenance Defined
What Planned Maintenance System Includes
Equipments 6 Big Losses
World Class Maintenance Management System
Different Approaches on Planned Maintenance
What Planned Maintenance Wants to Achieve
2 Phase 0 : Understanding The Need For A Planned Maintenance System

2.1
2.2
2.3
2.4
2.5
2.6
2.7
Build Up A Planned Maintenance Organization In Your Company

Defining Planned Maintenance Vision and Mission
Equipment Inventory and Machine Ranking
Maintenance Indices and Goals
Choosing Pilot Machine To Undergo Planned Maintenance
Basic Training On Planned Maintenance Overview
Maintenance Skills Upgrading
3 Phase 1 : Stabilize MTBF Through Restoration

2.1
2.3
2.3
2.4
2.5
The Need for Restoration

Step by Step Activities on Restoration
Recommended forms on Restoration
Conducting Audits
Replicating restoration on similar equipments
4 Phase 2 and 3 : Establishing a Maintenance System

4.1 Which Comes First Modification or Maintenance
4.2 Understanding Different Maintenance Categories and Tasks
4.3 Understanding Operating Condition of Equipments
4.4 Functions
4.5. Functional Failures
4.6 Failure Mode and Effect Analysis
4.7 Failure Consequences
4.8 Preventive Maintenance Tasks
4.9 Predictive Maintenance Tasks
4.10 Breakdown Maintenance Tasks
4.11 Failure Finding Tasks
4.12 Maintenance Algorithm / Maintenance Decision Diagram
4.13 Step by Step Activities on Phase 2 and 3
4.14 Recommended forms on Phase 2 and 3
4.15 Replicating Phase 2 and 3
4 Phase 4 : Lengthening Equipment Lifetime

4.1
4.2
4.3
4.4
4.5
Addressing Equipment Weaknesses through Improvement

Tools of the Trade
Step by Step Activities on Lengthening Equipment Lifetime
Auditing Phase 4 Activities
Replicating to Similar Equipments
Preface
Most industries today perform their maintenance on a firefighting or reactive mode, fix when it fails
syndrome, others called this the Bandaid Therapy. This generation of maintenance evolved during
the 1940s way before the Japanese bombed Pearl Harbor. Equipments at that time were simple
hence this type of maintenance does not seem to make an effect on production at all. But as time passed
by, more and more developments had been made, equipments are highly modernize and automated to
perform the task required, but still most Maintenance Managers cant seem to get away from the concept
of Reactive Maintenance. Most companies hire and look for maintenance people with adequate experience
of the equipment and not on the systems of maintenance, thats why there are only few people with such
understanding of the maintenance system.
Maybe you had been using the concept of Preventive Maintenance and have standards set forth and
followed overhauling or replacing some parts on a specific set of time indicated in the equipments manual,
and from time to time with your customers visiting your plant finding some loopholes in your system
try to add a couple of lists in your maintenance tasks, and you have 20 customers, hence before your
maintenance lists only compose of 10 activities now its up to 100. My question is does increasing the
activities of maintenance task ensures a higher reliability of your equipment or its the other way around ?
Perhaps doing more maintenance on an equipment will do you more harm than good in the long run.
I have studied and trained on TPM Methodology, RCM2 by John Moubray and implemented a prototype
team in one of our divisions, and after exhausting meetings we finally arrived with a comprehensive indebt
and true maintenance task that must be performed on their equipments, and this were product of
continuous brainstorming of the most experience people in their field which the team composed of. The
team had been stunned by their final report which minimize their activities by at least 100 inspections, so
when we set the time for it to implement the new system, the team were somewhat afraid, and implementation had been delayed. Later on I found out that most of the inspection items listed in their maintenance
tasks came from their customers and included in their maintenance standards or specs during customer
audit. I tried to talk to their superior, and finally after exhausting hours of explaining to them that this is a
more reliable maintenance task, they agree, but said that they cant remove the old task so they will do
them both simultaneously. This is like disposing your garbage and after doing it, you again put some more
garbage. finally, I told their boss and the team if your not going to perform what you know is right, then you
make your choice., The RCM data had been completed but never implemented in their division its in one of
the drawers of the team and maybe it will stay there until it become some scratch paper in the future.
Preface
Some lessons learned is that when making some changes in your maintenance task be sure to have the
guts to back it up since you might be facing some walls in front of you. I am referring here to customers,
equipment vendors, Quality teams where they will penalize you if you dont perform this task which is
included in the standards, be sure that the standards will be changed and these people must be educated
on the new system, I believe that increasing the number of maintenance task will not actually lead you to
a more better reliable equipment but its the other way around.
It is not easy to change a maintenance system that had been in your company for many years, but it is
possible for every company to transform from a reactive to a proactive stage, and this is the objective
of this book. I have detailed every step so you can follow them thoroughly. Let us face the facts about
your system of maintenance so we can learn from them. Many companies are struggling to survive
together with their competition, maintenance is one big factor where the company can save on cost if
one has sufficient knowledge to convert their maintenance task into a proactive one. I do not meant here
on cutting maintenance cost where Maintenance Manager disapproves all P.R. (Purchase Order) of parts
needed for a monthly Preventive Maintenance.
There is no such thing as overnight success or one day transformation, it will take you several months
and years of achieving a world class maintenance system so you can stay competitive in your arena.
Your greatest investment here will be time, but I guarantee that this will pay you off by reducing your
cost in maintenance. Make these changes now, not because you can sleep soundly at night without
your phone ringing and asking you to report to your plant due to unexpected breakdowns but because
every company that exists are on a survival mode. Millions of dollars can be saved and avoided on
maintenance by adopting a change in your system of maintenance some investments had to be made
and this is not where you should cut on costs. The first step in every change is getting yourself educated,
and attending trainings.
Having a good maintenance system is not about having the best maintenance software in town that can
automate your task, print them and have the lists on what your going to do. This is about how spare parts
behave and understanding them so you can determine the most appropriate maintenance task for that
part. This is about learning the basics and addressing basic equipment condition which had been neglected
These basic equipment condition includes cleaning, lubricating, bolting yet when you check your own
equipment, how many bolts are missing or not the same due to the number of times it had been repaired,
overhauled or undergone Preventive Maintenance Schedule. Perform the basic first before you can
advance to any improvement program.
So the question of what is the best maintenance system to adopt, the answer is doing the 4 Phases of
Planned Maintenance :
Phase 1 : Stabilize MTBF Establishing the Need For A Basic Equipment Condition
Phase 2 : Lengthening Equipment Lifetime Addressing Design Weaknesses
Phase 3 : Knowing when to use the different Maintenance Tasks on Hand
Phase 4 : Using Predictive Maintenance Technology
Preface
A Typical Day With Operations
Perhaps you had been called late at night to come back to the plant due to some failures the maintenance
cant handle, you came to the plant at about 3:00 am and it took you about a couple of hours to get the
equipment running, its 5:00 am now in the morning and it will take you a couple of hours to go home so
you decided to stay on the plant looking exhausted, your maintenance manager shakes your hand and
asked you how youd fixed it, chat with you over a cup of coffee.
Another typical experience is that production needs to deliver x output for the day then suddenly, a major
equipment fails, now maintenance is called to do the repair. You have not experience this fault or failure
before, and soon hours is passing by but still you cant fix the problem. The operation manager is now
worried and stays in your back, he becomes impatient and soon tells you what to do, and after following
him, the problem had been doubled. He starts to increase his voice , which creates a panic within you.
Or it had been a day when Machine no. 13 is due for a Preventive Maintenance Overhaul, you had
advise the operations on the said schedule through e-mail, but who cares, the time had come to finally
shut down the equipment, but operations wont agree, finally in order to settle the feud, you get a waiver
in your hand and let the operations sign it, in which the last part of the paragraph reads that whatever
happens to this equipment, maintenance will not be held liable, you give the form and the operations
manager place it in his upcoming files which is about 2 feet high,
C hapter 1
I Introduction on Planned Maintenance

1.1 Understanding The Need For A Planned Maintenance System
In every industry there seems to be a misunderstanding between operations and maintenance people.
The never ending saga of feuds between the production and maintenance people is evidently rampant
where maintenance accuse the operations of flocking their equipments to death and when the machine is
due for a Scheduled-Maintenance Overhaul, they endorse it to operations but it takes more than a shift
to get it in running condition, and this time its production turn to strike on their enemy. Does this exist in
your company ? Dont worry, your not alone. Does the maintenance lack skills in performing their duties,
or the system in place needs to be replaced.
Doing maintenance is a serious business since it can constitute to 3 to 50 % of production costs, and
without a good system in place, not only can it be costly but might affect your companys survival as well.
Some may advert to continuous improvement programs, modifications, purchasing the best maintenance
software in town, benchmarking other companies, cost cutting programs, but mind you each of them have
their own sets of limitation. Let me give you an example, in the company I previously work, there
seems to be a battle of programs, more than a dozen programs exists, TPM was in place and modifications and improvements was done, but the team missed out something, a very important point, the product
the equipment is capable of producing was going to be phase out in a couple of months, so as the machine.
And after a couple of months, the machine was pulled out, crated and stocked. Thousands of dollars, in
improvement cost were gone.
Developing a strategic maintenance system must be done 2 folds, both a short term and a long term
plan. The long term is where most maintenance managers and people lack, it is not sufficiently enough
that We Stop The Bleeding Syndrome neglecting the fact that possibility of other parts might be affected
which can take a month or more to take effect. A good maintenance leader always sees this aspect in 2
ways, both the short term and the long term plan.
The sad fact is when we compare equipments 50 years ago nowadays, we can see a more complex,
automated equipments, the change had been rapid, but the maintenance tasks performed most of the time
had not change from a firefighting or reactive (fix when it broke) still to a firefighting or reactive mode. And
when we speak of a strategic maintenance system that must be in place we must not only speak of lower
cost and higher availability, but a maintenance perspective on the following basis must be in effect :
Higher Plant Availability and Reliability
Greater Safety
Better product quality
No damage to the environment
Longer equipment life
Greater cost effectiveness
Therefore, in a nutshell, when we speak of a system of maintenance that would be a dream for every
Maintenance Managers which is to select the most appropriate techniques in order to deal with each type
of failure process in order to fulfill all the expectation of the owners of their equipment, in the most cost
effective maximizing its total Life Cycle Cost with the active support and participation of both operations
and maintenance together

Therefore, the concept and basic understanding of Planned Maintenance is essential, it is not a cure all
for your equipment problems, however, when you have applied the steps involved, not only can you have a
piece of mind where you can sleep at night without the maintenance shift supervisor calling you early in the
morning for a failure they cant handle, but a structured and effective Planned Maintenance system can
guarantee you that the machine is expected to perform on its optimum condition, and damages in cost
savings on repair and maintenance would thus be reduced.
Planned Maintenance is a long term solution for your daily day to day problems, we need to put a stop
on firefighting practices, an accumulation of such practice will hurt your plant financially, shorten the life of
your equipment, delayed deliveries to customers, long cycle time, high costs on spares. A company that
wants to survive with their competition and an economic slowdown must focus on a rigid framework on their
maintenance structure and strategy they must adopt the Planned Maintenance System.
1.2 Planned Maintenance Defined

TPM composed of 8 major pillars Autonomous Maintenance, Planned Maintenance, Office TPM,
Focused Improvement, Training and Education, Quality Maintenance, Initial Flow Control Activities and
Environmental Health and Safety. There are Chapters on JIPM (Japan Institute of Plant Maintenance)
books that covers the Planned Maintenance, and its definition varies from one author to another.
Planned Maintenance is the deliberate activity of building and continuously improving such a maintenance
System. by : Tokutaro Suzuki
Planned Maintenance is defined as maintenance activities performed on a pre-determined schedule of
activities. by Charles Robinson & Andrew Ginder
Although there may be more definitions on Planned Maintenance, I think that Suzukis definition is the
simplest way of defining it. Every company had their own system of maintenance in place, the job of
Planned Maintenance is to continuously improved such a maintenance system. Planned Maintenance is
a pillar in TPM which aims to achieve high reliability of equipments while minimizing maintenance costs.
These are achieved through proper application of all the maintenance tasks such as Breakdown Maintenance, Predictive Maintenance, Preventive Maintenance, Corrective Maintenance which we shall define
in the later part of the chapter, it also aims at targeting a complete zero reduction in unplanned breakdowns
1.3 What Planned Maintenance Pillar Includes

A complete strategy on Planned Maintenance includes a Master Plan for the 8 major activities involved
although the major focus would be on implementing the step by step activities on Planned Maintenance,
In 4 Phases. The best way to carry out Planned Maintenance activities is to set a a time frame of completion for each phase for JIPM having a Master Plan. It includes.
Guidance and support for Autonomous Maintenance Activities
Planned Maintenance 4 Phase Activities
Lubrication Management Activities
Setting Up the Planned Maintenance Structure
Spare Parts Management
Reduction In Maintenance Cost Activities
Enhancement and Upgrading of Maintenance Skills
Success in Using Predictive Maintenance Instruments

1.4 Equipment 6 Big Losses
Equipment losses vary from one another, below are TPMs lists of losses an equipment can suffer. This
does not include interruptions or downtimes caused by outside factors such as power, facilities requirements, operator skills, and others. It is important to note what type of losses your equipment encounter
most of the time and who should address them. It is recommended that each losses be treated separately
as this type of losses needs different types of people to be addressed. Each of the losses specified below
must not be addressed by the maintenance people alone, but by a cross selection of expertise.
Breakdown Loss
Sometimes called as Equipment Failure loss is a loss when machine stops due to loses in its specified
Functions. There are two types of breakdowns, Function Reduction Breakdown which is when deterioration of equipment causes other losses in function even when the equipment can still operate. Imagine
your car running, and stating that the primary function of a car is to travel from distance A to distance B.
It can comply with the function, but one of the cars headlight is busted, side mirror is missing, wheels hub
is missing, car have excessive oil leak due to damage in seal, cars aircon does not work, wiper is missing
and so on, but still the car can function and travel from distance A to distance B, this is what Function
Reduction Breakdown is and most equipments suffer this type of losses and it seems that most of the time
this type of losses are being neglected. These are breakdowns which account for the largest proportion of
overall equipment losses. The second one is Function-Loss Breakdown which is failure in which equipment
stops completely. These are losses in which production is stopped another term is unplanned downtime.
Breakdowns halt production, deliveries are delayed, quality problems arises, maintenance cost is
increased, a single breakdown can create havoc throughout the plant. Analysis in the breakdown failure
can be attributed mostly to human problems, basic neglection, design problems, lack of operator skills,
lack of repair skills. Thats why a basic understanding of the failure must be address thoroughly.
Breakdowns are caused by many factors, and most of the time slight deteriorations are overlooked which
Contribute highly to equipments breakdown. Improvement in equipment performance can be done by
Simple addressing minor problems such as loose and missing screws, abrasion, debris and contaminant
Are addressed. Zero unplanned breakdown can be established by addressing the following :
Prevent accelerated deterioration
Maintaining Basic Equipment Condition
Maintaining Operating Condition
Improvement of Maintenance Quality
Addressing rootcauses of breakdowns
Correcting Design weaknesses
Once a breakdown occurred be certain to possibly learn everything you can and studying the causes,
conditions, maintenance tasks involved, repair method, much can be learned to prevent it from happening.
The basic responsibility of each maintenance is not to repair breakdowns but to analyze what had caused
The breakdown problem and draw measures to prevent the recurrence of the problem. If this is not being
Performed, you will just be wasting your precious time on doing repairs and quick fixes on the same
problem over and over again.

Set-Up Loss
It is the time required to remove dies, jigs for one product, clean-up, prepare dies and jigs for the next
product, reassemble the equipment, adjust the equipment, perform trial runs and make further adjustments until product of acceptable quality is obtained. It begins when the production of one product is
Completed and ends when standard quality is attained on production on the next type of product being
Processed. Shigeo Shingos (SMED) Single Minute Exchange of Dies deals in techniques in reducing
Set-up time and adjustment time without reducing its accuracy. According to him, a good set-up time in
Manufacturing must fall between 10 minutes and below. Findings of Shigeo Shingo, why set-up time is
prolonged is due to the following :
Preparation of materials, jigs, tools and fittings
Removal and attachment of jigs, tools and dies
Centering and Dimensioning
Trial Processing and Adjustments
20 %
20 %
10 %
50 %
The first step in improving Set-Up is to distinguished activities that can be performed while the equipment is
running from those that can be performed only when it is shut down. Differential External from Internal SetUp. External Set-Up are those activities which can be performed while the machine is running while an
Internal Set-Up are those activities which can be performed only when the machine had been shut down
for conversion. The goal on Set-Up is to minimize the time to perform it, and one of the techniques is to
write down all the steps performed in doing your set-up, then converting Internal Set-Up to External Set-Up
This can be accomplished by using a standard one touch jig, compare the shapes of tools and jigs for
different products and consider preparing a standard jig that can be shared by all. Eliminate adjustments
during internal Set-Up time by using intermediate jigs.
Here are 2 steps that can be taken to eliminate the need for adjustment
In many cases adjustments can be scaled down simply by improving the precision of equipment, jigs
and tools. The accumulation of imprecise settings creates the need for many avoidable adjustments.
Standardize procedures. Lack of consistency in the standards for measurement, quantification, and
Other operation and maintenance procedures is another cause of unnecessary adjustments.
Set-up losses cannot be eliminated but they can be reduced dramatically, poor set-up can cause other
Losses such as breakdown, quality problems and it is best that procedures on each product set-up be
Standardize. One maintenance can set-up one equipment differently and might take 15 processes while
One may take as much as 20 to 25 steps. What is important is that whoever is performing the set-up
Procedure have a set of standards to follow. Much can be learn by knowing the difference between what
Are internal and external set-up practices and most of them only needs common sense
Tips on Shortening Internal Set-Up Time

Simplify clamping mechanism by using quick fitting jigs
Adapt parallel operations, 2 people working together can perform a set-up faster and more effective
Optimize the no. of workers and division of labor specially for large and complicated set-ups
Doing this simple basic steps will greatly reduce your set-up time

Eliminating Small Losses In Set-Up
What type of preparations need to be made in advance ?
What tools must be on hand ?
Are the jigs and tools to be installed in good condition ?
What type of workbench is needed ?
Where should jigs and dies be placed after removal ?
How will they be transported ?
What types of parts are necessary ?
How many maintenance people are needed to perform the set-up ?
Idling and Minor Stoppages

As equipment becomes more complex and automated, more losses are attributed with Idling and Minor
Stoppages (some companies term this as assists). First let us define this type of loss. A minor stoppage
occurs when a failure or an error in automatic handling, processing or assembly of parts and workpieces,
or an equipment stoppage due to the occurrence of quality related abnormality. This type of losses arises
mostly in automated processes and include the following :
Workpiece flow stops
Operator resets workpieces correctly
Operator reactivates process and machine runs
The problem with this type of losses is the number of occurrence or frequency, and most of the time this
type of error is left unrecorded since the time to fix it can be done by just resetting the buttons and it will
spend more time to record and write down the error. Idling and Minor stoppages sometimes are mistaken
for breakdowns, which must not be the case, these must be separated from breakdowns. These type of
losses can be addressed by Autonomous Maintenance through initial cleaning, JIPM experts believe
that having an equipment free from dirt and dust can reduced minor stoppages from 20 to 60%. While
more complicated minor stoppages which cannot be reduced through cleaning must be addressed by
a cross functional Focused Improvement team composing of engineers and maintenance people. Some
examples of Idling and Minor Stoppages includes a workpiece jamming, resetting of sensors, error reading
on monitor of computerized equipment where the machine is stopped temporarily, operator resets and
machine starts running again. This problems occur more frequently in automated equipments. In
addressing minor stoppages, ensure the following :
Observe what is happening. These can be done by carefully observing the equipment until an minor
stoppage had occurred and plan corrective measures
Correcting slight or minor defects defects, a small dent in the chute may be a cause of minor stoppages
and oftentimes we overlook this factor, maintaining a clean equipment can minimize stoppages
Design Speed Loss

Design Speed Loss is the loss production caused by the difference between the design or theoretical
speed and the actual operating speed. Lack of care at the design stage of the equipment may result
in speed reduction. Equipment is operated beyond its operating speed limit, quality defects and breakdowns are encountered. Although Japanese and Europeans systems of maintenance had conflicts

on this type of losses as later discussed in this chapter, Japanese TPM experts still consider this to be
a loss and according to them to reduce speed loss we must :
Level 1 : Achieve Standard Operating Speed for each product
Level 2 : Increase Standard Operating Speed for each product
Level 3 : Achieve Design Speed
Level 4 : Surpass Design Speed
Equipment may be run at less than the design or ideal speed for a variety of reasons which may contribute
to mechanical problems, quality and defect problems, history of past problems, and sometimes not knowing
what is the optimal speed. On the other hand deliberately increasing the operating speed actually
contributes to problem solving by revealing latent defects in equipment conditions.
Start-Up Loss
Start-Up loss is a type of loss that occurs until the start-up, running in and machine conditions of the
conditions of the equipment have been.
Start-Up Loss means that the material loss caused at the initial stage of production launching, namely
namely the loss caused during the period from start-up of production to stabilized production stage
Its frequency depends on several factors such as unstable machining conditions, poor maintenance,
and operator skills
Start-Up loss can also occurs after a poor set-up or conversion, after overhauling an equipment subject
subject to their Preventive Maintenance Schedule. It takes sometime for a machine to stabilize.
Start-up loss are difficult to identify. Their scope includes the stability of processing conditions, workers
skills and training, loss incurred by test operations and other factors. A thorough understanding of why this
type of loss occurs can be addressed through RCM2 or Reliability-Centred Maintenance which is covered
in Chapter 4.
Defect and Rework Loss

This is the loss caused when defects are found and the product have to be reworked. In general, these
defects are likely to be considered as a waste which should be disposed of but since even the reworked
products need wasted manpower to repair them. Included on this type of loss are products being shipped
back due to customer complaints. Products are returned and reworked in the production area.
Quality Defects and rework losses are caused by malfunctioning production equipment. In general,
sporadic defects are easily. Chronic defects require a thorough investigation and innovative remedial
Action. The conditions surrounding and causing the defect must be determined and then effectively
Controlled. Tools such as P-M Analysis is suitable in dealing with chronic problems, it aims at reducing
Defects to zero, however, P-M Analysis must only be used after extensive use of conventional tools
Had been used and around 1 to 5 % of the problems still exists, this is where P-M Analysis must be used
Ideally. Sporadic defects are easy to solve and it is more difficult to solve chronic defects.
Although other TPM books includes 8 Major Equipment Losses, the other two losses mentioned are
shutdown loss which means stopping the equipment for periodical or Time-Based Maintenance and Cutting
blade change which is loss caused by line stoppage for replacing grinding wheel, cutter, bits which might be
broken or worn out after excessive usage.

Responsibility For Each Losses
No.
Type Of Loss
1
2
3
Breakdown Loss
Set-Up Loss
Minor Stoppages
4
5
6
Design Speed Loss

Start-Up Loss
Quality Defects and Reworks
Responsible
Maintenance People
Cross Functional Team
Major - Cross Functional Team
Minor - Operators
Maintenance People
Indices / Measurement to Use

BDO and MTBF
Improvement In Set-Up Time, MTTS
MTBA and Frequency of Assist
No. of Output
Downtime Loss due to Start-Up
Yield
( Table 1-1 )
Overall Equipment Effectiveness

The main indices or measurement which can be use to track the improvement of equipment is know as
the OEE or Overall Equipment, however, for separate focused on improving each losses, I have detailed
on the above table the most appropriate measurement of indices in improving them and responsibility
for each type of losses. A cross functional team is a Focused Improvement Team composing of engineers,
Quality People, Maintenance Experts, Production Supervisors and Operator teaming up to solve the losses.
Team must compose of people with enough knowledge on the function and process of the equipment being
involved, as a person who do not have enough understanding even on the basic equipment condition may
not contribute to the problem they are solving. The goal is to determine which type of losses most of your
equipment suffers, set-up the team to improve on them and replicate this improvements on equipments
with similar problems operating under the same conditions. Note : While it must also be studied whether
the improvement must be done where marketability of the products is still in demand, equipment will still be
used for a number of years, decision as to whether improvements should be replicated on similar machines
under low loading, and other factors as modification, changes and improvement on equipments will cost
and entail companys money.
OEE = Availability x Performance Rate x Quality Rate x 100 %
Availability = improving availability will improve the number of breakdowns, reduce time to set-up
Performance Rate = will improve Minor Stoppages and Design Speed loss
Quality Rate = will improve defects and rework and start-up loss
OEE is the primary measure of performance in TPM. Calculating a true and meaningful measure is
extremely important to any improvement process. Equally important is the visibility and communication
of the measure to the people who can impact it the most. The higher OEE, the better the equipment is
in terms of availability, performance rate and quality rate. For single product equipment computing OEE
is simple, however for equipments processing 2 or more products, ideal cycle time for each product
together with the time each product was process must be known. This is the safest and most accurate
way to get the true OEE for that particular equipment rather than averaging. Target to achieve 85 % OEE
on your equipment, isolate which losses contribute most and set-up Focused Improvement team to work.

1.5 World Class Management System
When asked on what does it take for your maintenance system to be world class, the answer is having a
Pro-Active system of maintenance. Have you encountered this kind of maintenance meeting ?
Boss : Whats our status ?
Maintenance : Operations running smooth, but we encounter some abnormal vibration on machine 4,
its still running normal, and we estimate 3 to 4 weeks until a major breakdown can occur, so we are now
checking everything, spares availability, manpower needed, time it will be down will be couple of hours
at the most and we have notified operations and gotten their approval for the repair, and possibility to use
machine 9 as a back-up
Well if not, perhaps its the same old meeting where maintenance boss gets mad over the same kind of
problem and blames his people for not doing their job, and after the meeting another unexpected break-down
happens, and when it comes to reviewing the maintenance cost for the current month which is way
beyond their goals, maintenance boss orders not to list following parts that had been already used so it
can be carried over to the next month.
Let us define the difference between having a Pro-active and Reactive type of maintenance. In a Reactive
maintenance, meetings are held daily and discussed what had failed. Sometimes what is done to stop it
from happening, this means dealing with failures after they have occurred. While in Pro-active maintenance
From the book of

John Campbell, Uptime
Structure of a World Class
Management System
Level 3
Quantum
Leaps
Level 4
Process
Re-engineering
TPM
RCM
Continuous
Improvement
Figure 1-1
Level 2
Level 1
Data
Management
Measures
STRATEGY
Tactics
Plan and
Schedule
Control
MANAGEMENT
FOUNDATION
7
Leadership

we deal with events before they are likely to occur, this can be done by identifying all failure modes which
are likely to affect the equipment, determine what happens when it occurs and what should be done to a
anticipate, prevent, detect, predict or modify it out.
Reactive Maintenance
Failure Occurs
Pro-Active Maintenance
Action Taken
Action Taken
Possibility of Failure
To Occurs
1.6 Different Approaches on Planned Maintenance

JIPM Chapters on Planned Maintenance approach it on a 4 Phase Implementation Stage, and there is a
wide range on how to effectively apply the Planned Maintenance system, just to give you a glimpse of how
Planned Maintenance is applied to different areas and companies 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
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 / Linking Of Operations Daily Observation
with Maintenance Planning
Phase 4 : Pursue Predictive Maintenance And Forecasting Techniques
Reference : Harris Kuala Lumpur, Malaysia, Assembly and Test Operations

by : Adre Blanc
1994 :
1995 :
1996 :
1997 :
Breakdown Maintenance and Time-Based Maintenance

Established Planned Maintenance System (Automated Report System)
CMMS System
CBM On Selected Equipments
8
9

Reference : JIPM TPM Instructors Course 2nd Revision March 1996
Approach Towards 4 Phases Through Zero Breakdowns
Phase 1 : The Dispersion Of Reduced Or Extend 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
Removal Of Sporadic Failures
Restore Appearance Of Deterioration
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 5 Senses
Phase 4 : Prediction Of Failure By The Equipment Diagnostic Techniques
Failure Mode For Diagnosis
Extension of Lifespan By Technical Analysis Of Catastrophic Failures
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
I am showing you some of the variations on how Planned Maintenance adaptation varies from one another.
Whatever steps of phase you apply in your system of Planned Maintenance boils down to a 4 Phase approach
Phase 1 : Restoration and Establishing Basic Equipment Condition
Phase 2 : Lengthening Equipment Lifetime By Addressing Design Weaknesses
Phase 3 : Periodically Restore Deterioration
Phase 4 : Predict Equipment Life
Reference : Maintenance Consultant, Chairman of Studio Base Group

by Mario Giberton
Step 1 : Study The MTBF
Step 2 : prolong The Duration Of MTBF
Step 3 : Reduce MTTR (Mean Time To Repair)
Step 4 : Forecast The Duration Of MTBF
This are the 4 essential Phases of Planned Maintenance, whatever or how they are re-arranged, their ultimate
goal is to be Pro-Active with the use of sophisticated Condition-Based Maintenance Techniques or known as
Predictive Maintenance. Failures cannot be eliminated, however, what is important is that they can be predict-

ted when they can occur, what are the necessary plans to undertake to prepare for such a failure. To build
an effective Planned Maintenance System, maintenance personnel must be at a higher level of readiness and
perform more advance work than operators in the area of productive maintenance. They must be determined
through predictive and preventive measures never to permit failures or defects to occur. Their true tasks is not
carrying out repairs but in eliminating failures.
To begin your journey on Planned Maintenance, the first step will always be for maintenance people to undergo basic training on Planned Maintenance. If your plant is active in TPM, a facilitator should be the once to
conduct the training on Planned Maintenance, it must clearly be stated that the goal of maintenance is not
on how many equipments they had completed in undergoing their PM schedule, it is not how many repairs,
a maintenance technician had done, or how many parts theyve replaced within their shift, but rather a more
indebt understanding of the Basic Equipment Condition and its functions, there job is to educate operators
so that they can do minor repairs and set-up while they focus on more complicated and difficult chronic
problems. Most oftentimes, the machine needs surgical operation, but due to cost cutting budget constrains,
we perform the Band Aid Therapy. Believe me this is not the way to cut corners, instead of saving this will
induce you more cost in the long run. Having a system and investing in restoring equipment will be your
responsibility to have a heart to heart talk with your superiors, do not take this message lightly.
During one of my RCM2 trainings, a participant in Facilities asked me this question on what type of maintenance tasks can be done on AVRs, simply you cant open them and check every single electronic component, but I answered, if its function is critical, then the only maintenance you can have here is having a
Redundancy (In RCM terms redundancy means having a duplicate). The participant was not happy with
the answer I gave him since this will cost hundreds of thousands of dollars which management will not
Approved. I told him what will be the worst case when it fails, and said operation will stop and be halted.
Anyway making the story short, 2 years later, a fire occurred in one of the Plants which started from the
AVR, operation was stopped for more than a day. The lesson here is simple, if a single part or spare in
your equipment will induce you severe consequences, justify to your top management in having a stock
on hand, put into writing some cost comparison on if it is to fail and how it will affect your operations.
1.7 What Planned Maintenance Wants To Achieve

I always tell my participants during training that having an effective maintenance system is no different
than coaching a basketball team. Imagine if I am the coach and I put my first 5 with the smallest person
to be 6 8 then I will be strong on rebound, but definitely I wont be able to have an effective guard, because
all of them have the center position, or if I have a first five with the tallest being 5 10, then our statistics
shows we will be dominated on rebound. On the other side, your maintenance system must be balance,
if you have your centers, forwards, and guards in the team, then you have an effective team, likewise in
maintenance, if you know what parts will undergo breakdown maintenance, what parts will be on scheduled
preventive maintenance, and what parts are under predictive maintenance then you have the best maintenance system. Most of the time all your tasks are under Preventive Maintenance, this is like having all centers
in your team, balance them, if this is the case in your company then your maintenance is very costly.
10

Implementing a long term Planned Maintenance System will take years to accomplish, but its results is
what every maintenance personnel can dream of, its benefits will have effect on the following
Reduction In Maintenance Costs
Higher MTBF and Reduced Planned Breakdowns
Higher Equipments Reliability and Availability
Upgraded and Higher Maintenance Skills
Making Your Maintenance Pro-Active and Not Reactive
Will it be the same old ways on your maintenance groundwork's, or I have made you stop to think its
about time to change your maintenance system. Is it time to do some revisiting on your maintenance
checklist and check its effectiveness if it truly serve its purpose, or are they a waste of time in doing it
and the once that really need the overhauls and maintenance task are being neglected or not performed.
Why not think about the long term plans on your maintenance activities.
Planned Maintenance activities are essential for any manufacturing or industry with equipments and
the subject of maintenance must not be taken lightly. Most of the times this is neglected, while a company can hire the best maintenance manager truly capable of knowing every detail of the equipments he
manage but lack in approach and systems in maintenance. I emphasize strongly in the contents of this
book that it is 100 times better to have a maintenance system in place than having the best maintenance
software in town. Prioritize in having a system of Planned Maintenance built in your organization. If done
properly and correctly, this investment can impact you on saving cost which can amount to hundred of
Thousand to million of dollars in waste on maintenance.
1.7 Planned Maintenance in 4 Phases

Phase 1 : Stabilize MTBF through Restoration
There are 3 main activities in Phase which include Perform restoration, recurrence prevention of deteriorations uncovered and Standardization. All these activities aim at establishing Basic Equipment Condition.
deteriorations are exposed and corrected. Before conducting Phase 1 activities, equipment is subject
to accelerated deterioration and failures occur frequently. Deteriorations are left unchecked even if
maintenance are aware of it. These are perceived as normal and breakdowns cannot be eliminated
since boss does not approved request for purchase of spare parts which need replacement. This
attitude oftentimes spell disaster since one breakdown may lead to another causing more downtime
and money. Activities on Phase 1 aims at changing the concept of the traditional approach on firefighting
or reactive stage by doing the basics and restoring equipment to its original condition.
Prevent accelerated deterioration, this tasks involves extending the equipment lifespan by prolonging
MTBF or Mean Time Between Failure. The longer the interval for the time to repair the more the uptime
of the equipment is utilized. Begin by tagging the equipment for deteriorations and abnormalities uncovered
and correcting them all. Expect a dramatic reduction in Breakdowns once Phase 1 had been completed.
Analyze why deteriorations occurred and perform countermeasures to prevent the recurrence of
accelerated deteriorations. Simple why-why analysis must be performed at this level.
11

Phase 2 : Lengthen Equipment Lifetime
Once accelerated deterioration had been eliminated, 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
or Maintenance Prevention Design Form is usually used for this activity and later on feedback to the
IFCA or Initial Flow Control Activity Group 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. Us the equipments parts with design weakness are modified, this must run
in parallel in improving the skills on how the operator operate the equipment and how maintenance
repairing skills must be standardize as well.
Phase 3 : Periodically Restore Deterioration

A thorough study of the maintenance tasks must be done to establish the correct maintenance to be
performed. RCM2 is a perfect methodology for this concept. Not all parts need to belong to the
Time-Based or Preventive Maintenance Calendar System. This can be done by having a thorough
understanding on how such tasks can be performed correctly. Each part have their own failure
characteristic pattern. The key in this activity is to know the 6 failure pattern so you can derive the
correct maintenance tasks for each function through an Algorithm or Decision Diagram. In this activity
we are not dealing with equipments but a comprehensive maintenance system that must be adopted.
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 the Run-To Fail Tasks.
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 key senses of humans in a much higher perspective with the aid of
Instruments. Several parts of equipment can be predicted through the use of these techniques, this is
done by checking the condition of the equipment. The key on using these technique is to know the P-F
Interval which is explained later in the chapter, if a part shows symptoms these are good candidate to
use Predictive Maintenance in this regard. For example, a bearing may produce noise, increase in
temperature, increase in vibration, these are the symptoms that a failure is likely to occur. Therefore,
the maintenance can be well prepare for this occurrence. Advantage of Predictive Maintenance is you
can utilize the part to its maximum life without the need for a breakdown to occur. Parts can be replace
within hrs its going to fail, this is the essence and beauty of having a Pro-active Maintenance. Both
Predictive and Preventive are Pro-active maintenance once you know how to adopt them properly and
the key is to understand the 6 failure pattern curves.
12
C hapter 2
2 Phase 0 : Understanding The Need For A
Planned Maintenance System

Phase 0 details the requirements needed to set-up an effective Planned Maintenance System in your
company. These are the basic essentials needed for a strong foundation. Preparatory stage usually
takes from 1 to 3 months. It is very important not to ignore this stage, otherwise building a Planned
Maintenance System without establishing basic foundation is like building a house on a sand. It is best
for a company starting on Planned Maintenance to hire persons to act as Facilitator, that specializes
in this regard, I would prefer hiring since there are actually few people who give consultancy in this
regard. The important thing is that maintenance people must own Planned Maintenance and must not
be treated as a separate program from their day to day activities.
2.1 Building Your Planned Maintenance Organizational Structure

It is best that the whole Maintenance Department comprises the Planned Maintenance Organizational
Structure, some companies have a separate organization for line maintenance or sustaining group and
Preventive Maintenance group. Both must work together towards achieving a common goal. Top
Maintenance Manager must spearhead the Planned Maintenance Implementation, with close communication from the Planned Maintenance Facilitator or Engineer, whose function is to develop the legwork
needed, conduct trainings on Planned Maintenance, set-up the teams, and anything related to it. If your
company is big with different divisions, it is best to set up a working Planned Maintenance Committee
who shall represent their division, a maintenance section manager usually is best suited for this position
Top Maintenance Head
Division 1
Division 2
Section Manager
Sustaining / Line Mtce
Section Manager
Maintenance
Division 3
Centralize
Centralize
Section Manager
Section Manager
PM Group
Section Manager
Facilities Group
Maintenance
Maintenance
Maintenance
Maintenance
2.2 Planned Maintenance Kick-Off

This can be done by simply having a general meeting for all maintenance personnel and Top Maintenance
Manager announces the launching of Planned Maintenance in their organization. Some companies provide
foods, slide shows, inviting guest speakers specializing in the subject matter, spend 2 to 4 hours for this
launching. Explain to your people the need for launching this program.
2.3 Define Roles and Responsibilities

Planned Maintenance Facilitator defines the roles and responsibilities of each member of the maintenance
team. Each member involved must have an active part in the Planned Maintenance implementation from
the top to the lowest ranks in the maintenance group
13

There are several points to be taken out if you are serious in Planned Maintenance Implementation
1st, during the preparatory stage, all divisions in the Planned Maintenance must be involved and participate
2nd Top Management must not only support but own the Planned Maintenance Activities. These are 2
different words that will spell success or failure on your implementation. This is a long term solution
on your day to day problem on Maintenance. Not owning a program besides announcing it will create
impact on all maintenance people enough to loose their enthusiasm.
3rd Include your Facilities on your Planned Maintenance Program as they will play a vital and important part
as explained in the later part of the book
th
4 Doing TPM activities involved investment in time and money, be sure to support it. This will hurt as
as you control your maintenance cost, but this will pay you off in the long run. Imagine a team conducting
restoration and found out several parts that had been neglected and prepares a Purchase Order only to
be denied. Give priorities and approve the once that really need to be restored.
Below are some guidelines to help you and the facilitator on the different responsibility each plays.
Roles and Responsibilities Of Top Maintenance Manager

Launches the Planned Maintenance implementation in the company
Conduct review with the PM Committee selected ( weekly or bi-weekly)
Track progress of completion on each activity involved in Planned Maintenance
Approves logistical support and requirements needed by the teams
Must own a at least one Model Team
Provide simple recognition to teams that completed each Phase with good results
Review overall indices set forth by the Planned Maintenance
Roles and Responsibilities Of Planned Maintenance Facilitator

Define roles and responsibilities for each maintenance involved
Conduct trainings on Planned Maintenance Steps
Guide the team in their implementation
Conduct Initial Audit together with the Maintenance Section Managers for each Phase completion
Planned Maintenance facilitator must act as consultant on Planned Maintenance
Roles and Responsibilities Of Maintenance Managers

Must own a at least one Model Team
Review logistical support needed by their team and elevate them to Top Management
Conduct Audit on their Teams completion and Machine Certification
Review the teams on their Planned Maintenance Journey
Summarize results obtained from implementing Planned Maintenance
Set-up goals on maintenance indices, completion stages
Attend trainings on Planned Maintenance
Roles and Responsibilities Of Maintenance Pilot Teams

Complete the Planned Maintenance Activities
Provide OPLs (one point lessons) to Operators and Fan-Out Teams
Attend trainings on Planned Maintenance
Monitor equipments performance and results as they complete each Phase activity
Set up a bulletin board and update them to show their activities performance
Serve as a model to other teams and provide guidance and education on other teams
Generate standards on maintenance and revised existing standards or specs
Train operators on Basic Equipment Operation and Condition
14

2.4 Set Up Vision and Mission for the Planned Maintenance
This will be your creedo that every maintenance personnel will carry out and be guided by. It shall be
your ultimate direction you are aiming for. Be sure that this is observe and that all activities that you
perform on your Planned Maintenance activities relay to in achieving your Vision and Mission.
2.5 Generate The Planned Maintenance Master Plan

A Planned Maintenance Master Plan is where you put the activities with their timeframe of completion.
It is a piece of the cake for the overall TPM Master Plan, below is an example of a PM Master Plan.
SAMPLE - PLANNED MAINTENANCE MASTER PLAN

INTRO
IMPLEMENTATION
2000
MASTER PLAN ACTIVITY
NO.
2001
2002
FULL DEVELOPMENT
STABILIZE
2003
2004
ZERO BREAKSDOWN ACTIVITIES
Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4
PM 7 STEP JOURNEY
Step's 0 : Preparatory Stage
- Machine Ranking
Step's 1-3
- Initial Cleaning, Restore, Standards
Step 4 - Corrective Maintenance

- Countermeasure for Design Weakness
Step 5 - Preventive Maintenance

- Periodic - Preventive Maintenance
Step 6 - Predictive Maintenance

- Overall Audit and Diagnosis
Step 7
3
3
4
5
6
7
SUPPORT ACT
MTCE CONTROL SYSTEM
- Machine Ultimate Utilization
SPARE PARTS CONTROL
PLAN
Machine are categorized as Rank A, B
ACTUAL
PLAN
Attain ZERO Breakdown for all Rank A and Rank B Machines
ACTUAL
PLAN
Apply P-M Analysis on Recurring Breakdowns and Feedback to IFCA
ACTUAL
PLAN
Final Inspection Standards - Time Based Maintenance
ACTUAL
PLAN
Utilize Condition Based Maintenance Instruments & Techniques
ACTUAL
PLAN
ACTUAL
Review and Improve Spare Parts Control and Utilization
PLAN
ACTUAL
MAINTENANCE COST AND

BUDGET CONTROL
MAINTENANCE INFORMATION
MANAGEMENT & CONTROL SYSTEM
MAINTENANCE WORK PLANNING
AND MANAGEMENT
GUIDANCE AND SUPPORT FOR
JISHU HOZEN
MAINTENANCE SKILLS
ENHANCEMENT
EVALUATION OF THE PLANNED
Review Maintenance Cost Control and Utilization
PLAN
ACTUAL
PLAN
ACTUAL
Review PM System
PLAN
ACTUAL
PM Guidance and Support for Jishu Hozen Activities
PLAN
ACTUAL
PLAN
ACTUAL
PLAN
2.6 Conduct Machine Inventory and Rank Equipments
Figure 2.1
List all your equipments by preparing a Machine Inventory Lists ( appendix - ), and conduct a machine
ranking for all equipments. Rank A will be the worst and Rank C as the good machine. Only machines
that are rank A and B should undergo the Planned Maintenance activities. Prepare a category for each
equipment and rank them accordingly. Perform this on all your equipment lists.
Definition of breakdown must be clear to our Maintenance people and it must not be confused with Minor
Stoppages or Assists. Planned Breakdowns or Schedules Time Based Maintenance must not be considered
as breakdowns since they are Planned downtime. Once completed a summary of figures on machine
ranking will give the maintenance team adequate data for their selection of their 1st pilot machine that will
15

undergo the 4 Phases of Planned Maintenance. This also gives the maintenance people which equipment
to focus on improving them, remember the goal of maintenance is to improve equipments that seems to
fail frequently. These machines will be the focus on Planned Maintenance
Included As Breakdowns
Actual conversion and set-up

Machine Stoppage caused by Idling and Minor stoppage (Mostly, errors, jamming due to dirt, etc.)
Machine downtime caused by Preventive Maintenance Schedule such as overhauling of parts
Machine downtime caused by replacement of parts as reflected from the tool algo (Stroke-Based Mtce) schedule
Repairs and stoppages attributed by Predictive Maintenance Findings
Machine stoppage caused by audits
PM Schedule, shutdown of equipment , all Planned downtime
No inventory and all non-machine related downtime
Following Must Not Be Included As Breakdowns

Breakdowns caused by poor set-up and conversion, replace parts due poor set-up & conversion
Breakdowns caused by defects and reworks, ex. Worn-out punch producing defects
Function loss breakdown due to no available of spares
Unscheduled repair or overhauling of equipment or replacing of parts
Breakdown due to poor operator and maintenance skills
Machine stoppage caused by Facilities unexpected interruption
Category On Machine Ranking

Rank A Machines : Failure occurrences of more than 2x per month
Rank B Machines : Failure occurrences of less than 2x a month
Rank C Machines : No Failure occurrences
PM 7 - STEP ACTIVITY COMPLETION PLAN

Sa Planned Maintenance, Isang Misyon, Isang Direksyon . . . . .
PM STEPS
2000
COVERAGE
Q2
Step 0
Plan START
Necessity of PM
n.a.
Actual
Step's 1-3
Rank A & B only
Plan
S1 - Initial Cleaning
Rank A = 486
Actual
S2 - Restoration
Rank B - 941
Q3
100%
2001
Q4
END
Q1
Q2
Q3
2002
Q4
Q1
Q2
Q3
2003
Q4
Q1
Q2Figure
Q3 2.2
Q4
CLASSIFICATION OF MACHINES THROUGH RANKING
100%
START
2%
4%
19%
44%
2%
4%
23%
44%
70%
RANK A
84%
89%
93%
96%
98% 100%
END
RANK B MACHINES
S3 - Standardization
Step 4
Rank A & B
Plan
S4 - Countermeasure
Machines
Actual
START
0%
2%
4%
10%
10%
19%
25%
40%
50%
60%
START
0%
2%
4%
10%
10%
19%
25%
40%
50%
60%
2%
4%
10%
19%
25%
40%
50%
START
2%
4%
10%
19%
25%
40%
for Weak Points
Step 5
S5 - Periodic - Prev.
Maintenance
Step 6
S6 - Overall Audit
By Equipment
Plan
Type / and per
Actual
Sub-Assem bly
By Equipment
Plan
Type
Actual
START
and Diagnosis
Step 7
By Equipment
Plan
S7 - Machine Ultimate
Type
Actual
Utilization
16

Equipment may differ from one industry to another, and gravity or severity of failure varies accordingly
weight heavily if equipment have sever effect on safety and environment. Equipments that will undergo
Planned Maintenance activities must belong to either Rank A and B only. Other factors to be considered
in performing your machine ranking are as follows :
Safety and Environment What effect on failure does it have on peoples safety and their environment
Rank A - If equipment poses explosion or risks in killing someone
Rank B - If equipment failure might adversely affect peoples safety and environment
Rank C - If it does not pose any threat at all
Quality What effect on failure does it have on Product Quality
Rank A - Equipment failure had a major effect on quality
Rank B - Equipment failure produces variation on Product Quality
Rank C - Equipment failure have no effect on Product Quality
Operations What effect on failure does it have on Production
Rank A - Equipment failure had a major effect on production, no standby unit in place
Rank B - Equipment failure poses partial shutdown
Rank C - Equipment failure have no little or no effect on production
Maintenance Time and cost of repair
Rank A - Equipment failure takes 4 hrs or more fails 3x or more times per month
Rank B - Equipment failure takes less than 4 hrs fails less than 3x per month
Rank C - Equipment failure can be left unrepaired until a convenient time occurs
2.7 Select Pilot Machine and Backtrack Breakdown Data

A good indices for tracking Planned Maintenance activities are BDO (Breakdown Occurrences) and
MTBF or Mean Time Between Failure.
Definition of MTBF
MTBF - reliability engineering term that means the average amount operating time between the Occurrence
of breakdown that requires repair. The higher the equipments MTBF the higher the equipments reliability
MTBF
Mean
Time
Between
Failure
17

Determine your 1st Pilot Machine which must belong to Rank A or worst machine in terms of breakdown.
It is best that pilot machine have similar equipment types belonging to Rank A or B for Horizontal Replication purposes or fan-out of activities. After deciding which equipment will be piloted, backtrack data on
breakdown by checking history logs and records, backtrack BDO (Breakdown Occurrences) for 3 to 6
months as this will be your benchmark and reference as well as measure of performance on your activities.
It is important that the team monitor the data on Breakdown and provide a form on its occurrence, here is
a sample of Breakdown Report Form you can translate this to graph later on. Both BDO and MTBF are
being tracked. And one good thing about this form is this one sheet of paper can be used for 1 whole year.
BACKTRACKING MACHINE BREAKDOWN HISTORY

4
TOTAL
WW
TOTAL
WW
10
11
12
13
TOTAL
DT (Hrs)
11
10
DT (Hrs)
11
10
BDO
21
25
DT (Hrs)
BDO
28
26
BDO
33
20
52
51
50
BDO
14
14
18
47
1.4
P ICK
13
19
46
1.5
BOND
20
45
1.6
OUTP UT ELEVATOR
21
44
1.7
INDEXER
34
1.8
WAFER LOADER
14
26
25
20
13
12
0
(DT-Hrs
TOTAL WW
43
103
134
208
256
278
248
##### ##### ##### ##### ##### #####
##### ##### ##### ##### ##### #####
BDO
WW
128
(DT-Hrs
BDO
MTBF
MTTR
42
41
40
0
0
TOTAL
(DT Hrs)
0
0
WW
TOTAL
BDO
39
38
37
36
35
September
33
32
August
31
STATION
(DT Hrs)
0
0
WW
TOTAL
BDO
34
DIVISION :
SSEAL-FOL
DIE ATTACH
BDO
(DT Hrs)
30
29
28
27
TOTAL
26
25
12
24
13
Total BDO per

Sub-assembly
Overall MTBF/MTTR
Data for the month
June
20
23
25
26
22
TOTAL
Total BDO
Occurrence
for the month
TOTAL WW
Dec
Total BDO for a

particular sub-assy
per month
Different machine
sub-assemblies
May
Nov
Oct
40
Sept
Aug
Jul
Jun
May
Apr
Mar
Feb
16
BDO SUMMARY PER MONTH

Jan
103
11
BDO
DT (hrs
20
TOTAL
12
BDO
IP S
December
49
48
DIS P ENS ER
1.3
(DT-Hrs
1.2
TOTAL WW
TOTAL WW
17
16
Lists of machines
being tracked
April
15
November
14
INPUT ELEVATOR
October
WW
1.1
TOTAL
12
DEC
11
NOV
BDO
10
OCT
DT (hrs
9
SEP
28
8
AUG
S E C T IO N
13
7
JUL
6
JUN
14
5
MAY
4
APR
3
MAR
2
FEB
SUB-ASSEMBLY NAME JAN
S a Planned Maintenance, I sang Misyon, I sang Direksyon pa rin . . . . .

Swissline #1, 3, 4, 6 &11
FAN-OUT MACHINE :
Total Machine Downtime

in hrs for the week
March
BDO
February
DT (hrs
TOTAL
January
WW
Figure 2.3
WW
July
S1-01F
It is important that you divide your Pilot Machine into different major sub-assemblies and breakdown
must determine what sub-assembly did it occur. This will tell you which is the worst sub-assembly in terms
of breakdown so you can prioritize your Planned Maintenance Activities into that sub-assembly. Data listed
above data must only include unplanned downtime caused by breakdowns.
MTBF Mean Time Between Failure =
MTTR
Mean Time To Repair =
(Operating Time Machine Downtime) hrs

Breakdown Occurrences
Machine Downtime in hrs
Breakdown Occurrences
18

Both MTBF and MTTR must be expressed in hours. Operating time refers to the time the equipment is
operated and is different from available time which is the given time in a shift (8hrs), a day(24 hrs), a month.
(720 hrs), Operating time can be equal to the available time if the equipment is running at full capacity or load.
If equipment runs only at 80% capacity due to no inventory factor then,
Available time in 1 shift = 8 hrs
Operating time in 1 shift = 8 hrs x 0.8 = 6.4 hrs
Since the denominator of MTBF and MTTR is BDO or breakdown occurrences, if you achieve a zero
breakdown for a given week, both MTBF and MTTR is zero since any number divided by zero is infinity,
There are 2 choices to make if this is the case :
1st choice is to prolong your data from weekly to monthly, disadvantage is that MTBF and MTTR is
usually expressed in graphical terms where MTBF the higher the value the more reliable the
equipment is while MTTR the lower the value means that the time to repair the machine is fast.
Monthly data may not be accurate since it is possible to achieve zero breakdowns in a given month
then data for MTBF and MTTR will again be prolong again.
nd
2 The best way to cope with this situation is if case you achieve a BDO of zero then always assume
a BDO of 1 any number divided by 1 will give you the numerator itself which means that in a given
month you achieve a zero breakdown, then 720 divided by 1 will give you 720 hrs which means that
the machine have a perfect uptime with zero breakdown. 720 hrs is the highest MTBF you can
achieve for a given month of 30 days, for months with 31 days this shall be 744 days.
2.8 Determine Basic Training Requirements for Pilot Team

Planned Maintenance Facilitator in your plant must see to it that all members of the team are trained on
Basic Requirements needed to undergo each step/phase. It is best that these trainings be conducted in
house and hiring a Planned Maintenance facilitator which specialized in this field. Here are what I think
are the basic trainings on Planned Maintenance that the teams must complete as they advance to their
next step/phase of implementation in their journey. These trainings does not include specialization trainings on their equipment as trainings may differ depending on the type of plant and equipments,
Phase 0 Training Requirements

Planned Maintenance Overview (4 8 hrs)
Understanding The Need For A Planned Maintenance System
What Planned Maintenance Wants To Achieve
Summary of 4 Phases Of Planned Maintenance
Different Types of Maintenance Tasks
Why Do We Need Planned Maintenance ?
From Reactive to Pro-active Maintenance Tasks
Roles of Maintenance and Operations on Equipments
Phase 0 Preparatory Stage for Planned Maintenance (4 hrs)

Steps and activities needed for Planned Maintenance Preparatory Stage
Categorizing Breakdowns
Development of A Planned Maintenance Master Plan
Importance of Machine Ranking
19

Planned Maintenance Phase 1 Training (4 hrs)
Detailed Activities Needed To Perform Phase 1
Recommended forms to be used for Phase 1
What Phase 1 wants to accomplish
Understanding Basic Equipments Condition and why Restoration is needed
Difference between Initial Cleaning performed by Autonomous Maintenance
Poka-Yoke (Mistake Proofing For Zero Defects) (4 8 hrs)

Usually address problems caused by humans by providing solutions that are foolproof
Why-Why Analysis (2 hrs)
Simple analytical approach on analyzing problem rootcauses
6 Equipment Big Losses (4 hrs)
Understanding equipments different types of losses
What must be included as breakdowns and what must be excluded

Phase 2 Training (4 hrs)
Lengthening Equipment Lifetime By Addressing Design Weaknesses
Detailed Activities and Recommended forms to be used
Audit Procedure for Phase 2 and System for Horizontal Replication
P-M Analysis Training (4 hrs)

Problem Solving Technique for dealing with chronic problems
Initial Flow Control Activities

MP Design Improvements

Phase 3 Training RCM2 Methodology (3 days)
Basic Understanding on Different Failure Patterns
RCM Information Worksheet
How to Use The RCM Decision Diagram
Developing Equipments Maintenance Tasks
Predictive Maintenance Overview (4 hrs)

When To Use Condition Based Maintenance Techniques and Common Types of CBM
Techniques

Vibration Monitoring Techniques Seek Outside Specialization Courses
Thermography Monitoring Techniques Seek Outside Specialization Courses
Lube Oil Analysis / Tribology Seek Outside Specialization Courses
Others as seen on your maintenance tasks
Trainings is an essential factor that is required for the success of Planned Maintenance. As each team
completes each step/phase in the Planned Maintenance implementation, their skills are enhance and
they gain more knowledge and indebt understanding on the daily needs of their equipments. One factor
that is often overlooked in the process of maintenance is the use of the right maintenance task, putting
everything on time based inspection and preventive maintenance schedules. There are lots of industries
20

that do not use condition-based maintenance, and there are many maintenance people who have never
heard this concept, since they are too busy dealing with repairs and failures. Invest the time needed for
these trainings, these are investments your company needs and when each had been applied, whatever
time and money you have spend in them will be return to you 10 to 100x fold. Although one caution
the maintenance manager must make is that as each of the team members upgrade their skills, they will
be more marketable to other industries and even abroad, hence, it is best that whatever learning they
learn must be applied to your company, having a contract or including these in their yearly performance
appraisal will be a good option.
Summary
Phase 0 is the foundation of building a solid Planned Maintenance structure, aim at completing this initial
stage and determine a timeframe of completion. These are the basic activities needed for you to start a
strategic maintenance program.
Not all equipments will undergo each step/phase of Planned Maintenance but rather only those which are
classified and rank as A and B. The aim of Phase 0 is to plan ahead your activities on Planned Maintenance,
create a Timeframe of completion. It will take 1 to 2 months to complete this stage. Once the planning had
been achieved, your next step is to proceed to the details step/phase activities of Planned Maintenance.
Phase 0 Activities : Understanding The Need For A Planned Maintenance System

Activity
Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8
1. Building Your Planned Maintenance

Organizational Structure
2. Planned Maintenance Kick-Off
3. Define Roles and Responsibilities
4. Set-Up Vision/Mission
5. Develop PM Master Plan
6. Conduct Machine Inventory and
Rank Equipments
7. Select Pilot Machine and
Backtrack MTBF/BDO Data
8. Define Basic Training Modules
per Phase of Implementation
Table 2.1
21
C hapter 3

A machine that had been left unattended suffers from accelerated deterioration, it is both the responsibility
of operators and maintenance to establish basic equipment condition on their equipment. Whatever
program that you undertake once Basic Equipment Condition had not been established, then it is hopeless
to pursue such a program. Maintenance department often have no time to perform Planned Maintenance
because they are busy dealing with their day to day failures. It is impossible to established Planned
Maintenance in this situation. Oftentimes due to the equipment running continuously non-stop for 24 hrs
a day, 7 days a week, these simple basic condition had been neglected.
Dust, dirt and abrasion
Poor working environmental condition
Severe leaks and contamination
Corroded pipes and internal part of machines
Not calibrated and non-working gauges
Non-functional parts or Function Reduction Breakdown of parts such as sensors
Corrosion of metal parts and cracks
Missing bolts and nuts due to assembly and disassembly and so on
3.1 Understanding The Concept Of Machine Deterioration
Many parts failed to reach

their expected lifetime since
Basic Equipment Condition
had not been established.
phase 1 aims at eliminating
accelerated deterioration so
that parts reach natural
deterioration stage.
DETERIORATION
Natural
Deterioration
Accelerated
Deterioration
Point that part

Is expected to
Reach failure
Point 4
Point 1
Figure 3.1
Point 2
Point 3
Failure
Line
TIME
Time-Based
Condition-Based
Failed State / Run To Fail
22

In figure 1, a part or spare is expected to wear out at a specific point in time which in this figure is referred
to as Natural Deterioration, but due to neglect in Basic Equipment Condition, the part or spare fails even
before reaching its life, which is Accelerated Deterioration. The difference between point 1 to point 3 is
the amount of time you could have saved. This is the objective of Phase 1, bring all parts to natural
deterioration and avoid failures caused by accelerated deterioration, and once it had been restored all
measures must be done to prevent recurrence of the same problem.
3.2 Difference Between Restoration and Improvement

Our basic goal in Phase 1 is to eliminate accelerated deterioration by bringing the equipment back to
Its original condition. Restoration is simply replacing the parts and not modifying it, we shall leave the
Subject of modification in later phases/step in Planned Maintenance. What is important in this Phase is
That parts with deteriorations are replace, therefore when we speak of restoration we simply mean,
Establishing Basic Equipment Condition means eliminating the causes of accelerated deterioration
Machine is divided into different sub-assemblies and audited on its current condition
Basic Equipment that must be established must not be broad, if possible should be specific by indicating
numbers and parameters
For the Autonomous Maintenance Basic Equipment of the machine means it is well cleaned, lubricated
and tightened
Any activities performed to bring back the equipment to its original condition
On the other hand, modification or improvement means changing sometime out from the original
specification of the parts or spare, this is usually done when machine suffers from design weaknesses
These are improvements, modification or countermeasure done after analyzing its root cause to
ensure that deterioration had been eliminated and prevention of recurrence. Example : Oil Leak :
Analysis on grade of oil to stand temperature increase or change in a higher resistance oil seal while
a restoration task involved means replacing the seal with the same type.
3.3 Perform Initial Cleaning

While Autonomous Maintenance perform initial cleaning and Tag the abnormalities, the PM team
likewise is not exempted from this step, the main difference between the initial cleaning performed
by operators and maintenance is AM teams focus on the exterior part of the machine, while the PM
group perform their initial cleaning on the interior part of the machine, accumulated dirt, dust, rust,
corrosion, leaks will be the focus of the PM Teams restoration activities. PM team must lists all
deteriorations uncovered during their initial cleaning stage and correct them one by one.
Note for Autonomous Team : While most of the deteriorations include peeled off paint, Do not spend
the time to repaint the machine which most of the times is included in their abnormality tasks is not
highly recommended, instead, Autonomous Maintenance teams must focus on prevention and what
cause the peeled off paint.
Thorough cleaning means taking equipment apart to clean internal parts that you have never been
exposed before, this kind of cleaning naturally leads you to discovering deteriorations on the equipment.
overtime you will learn the correct way to inspect equipment for deteriorations and distinguish them
from normal conditions. By performing initial cleaning we address the following :
23

On the Equipment
Dirt and dust on equipment
Equipment leaks on hydraulic fluid and lubricants
Overflowing oil pans
Cutting debris scattered beneath the equipment
Layers of oil mist on motors
Strange noise on motors, overheated motors
Too much vibration on some equipment parts
Clogged drains and pipes
Unharness wires and octopus wiring connections
Oil leaks on floor and machine compartments
Dirty and disorganized dies and fixtures
Broken and missing gauges
Rust and corrosion on equipment parts and pipings
Worn out or overused parts and spares
Malfunctioning parts in which equipment still runs
Dirty and dead sensors
Maintenance Room Area

Disorganized maintenance bays
Slippery floors and cabwebs on the ceilings
Improper storage of spares
No fix location of tools
Disorganized files and bulletin boards not updated
Disorganized spares cabinet, no proper labeling
Many breakdowns occur because of lack maintenance are too busy dealing with the failures themselves.
performing basic restoration on equipments can dramatically reduced breakdowns by as much as 50%
and in some industries even more. Most industries make it a habit to clean their equipments and workplace
when they know that there will be an audit by one of their customers or one of your Top Boss schedules
the operation for a visit. Planned Maintenance must not be done this way to satisfy others, in fact basic
operating conditions such as maintenance the equipment clean is done to satisfy the user of the equipment.
Thats is correct, we perform maintenance so as to satisfy the requirements of the user. Often times
negligence on these basic factors happens because people perceived breakdowns as normal and as
part of their routines. They are custom to perform repair and fixes on equipments as part of their basic
job. Performing Planned Maintenance requires a change in direction, a change in the way people think,
a change in the way people act, unless these changes are accepted by all levels of organization in the
maintenance department, and are willing to perform the necessary steps required for such a change can
spell the difference of success in such an implementation.
Restoration plays a crucial factor in Planned Maintenance, and Top Management must support this
activity as there are cost factors involved in such undertaking. Imagine you have been approved of a
loan and you purchase a second hand car, you try to inspect and perform initial cleaning on your 2nd
hand car and perform restoration on these items so that you feel more confident driving your car. Same
thing goes with your equipment which had been running non-stop to cope up with output measures.
24

There are functional reduction breakdowns that need to be analyzed and restored, often times this
does not affect the operation of the equipment however they serve a function in particular. Spend the
Time to correct and restore these basic functions through Phase 1 of Planned Maintenance.
3.4 Detailed Drawing of Equipments Sub-Assembly

It is highly recommended that a drawing of the major sub-assemblies be done by the maintenance
Group. There are two purposes of doing this, first so that we can place a mark on where each
Breakdown occurs for easy reference by all maintenance involved and secondly, this serves as your
Training materials later on for teaching the Autonomous Maintenance group once they are in place.
Imagine the level of knowledge an operator may have once maintenance teach them these drawings.
These can aid as a communication in pinpointing the exact location of the failure which occurs frequently
Operators knowing the parts of his equipment can facilitate easy communication during what problems
had occurred in their equipment, and later on, you can teach operators to perform some basic minor
repairs, having you more time to focus on improving more sever failures.
3.5 Analyze Deteriorations and Prevent Recurrence Of the Failure

After completing your lists of deteriorations, teams meet and discuss each deterioration uncovered and
perform a simple why-why analysis on why each deterioration that had occurred and single out countermeasures to prevent recurrence of the problem. Most of these deteriorations had been neglected and
As the meeting progress, basic equipment condition of the equipment is taking place. Maintenance
Now understand why these deteriorations occurred in the first place, and what effect does it have on
their equipment, although some parts restored may have no relation to breakdown and are considered
as functional failure reduction, they may contribute to some problems of the equipment.
3.6 Document Evidence Before and After

Since we are implying a TPM concept of implementation on Planned Maintenance, a before and after
picture is required, these serve as your document on completing each restoration activity and can serve
as teaching aid to other teams and operator performing autonomous maintenance. A Digital Camera
will be useful in this tasks. The goal of the team is to correct all the deteriorations uncovered during their
Initial cleaning stage.
3.7 Standardization of Documents

Standardization of documentation is an activity in Phase 1 where each deterioration uncovered is being
crossed checked in to your existing Preventive Maintenance Checklists if a suitable task is performed and
why such tasked had been overlooked. If no standards had been made then a temporary inspection
standard is performed and a tentative revision of your PM checklist must be done. Objective of this activity
is to include all deteriorations that are uncovered, with a timely inspection and frequency which must be
made specially when he consequences of the failure is severe. The standards listed here are tentative
standards and must be performed on the specified date provided, also indicated in this activity is who is
the best responsible person to perform this inspection whether maintenance or operators.
If the responsibility is to be performed by the operators of the equipment, it is very important to educate
and train the operator through visual aids such as OPL (One-Point Lesson) or GTF (Good to Find) forms
so that operator understands why they need to perform such tasks. If Autonomous Maintenance is not
performed regularly or no activity exists, operators think that this is an added burden to them and find
maintenance passing the job to them, these must be explained to them carefully since they are the once
closest to the machine 90% of the time.
25

3.8 Planned Maintenance Activity Board
Although JIPM Consultants require both the Autonomous and Planned Maintenance to have their own
activity board in place. Activity boards is used to highlight the activities of the teams and their progress,
important factor here is the Breakdown Trend where after completion of restoration a drop in breakdown
is evident. Not only does this serve to highlight the teams progress, but it serve as reference to all maintenance and operators that by seriously performance the basics of Planned Maintenance, breakdowns
are reduced dramatically. The goal of Planned Maintenance is to minimize Unplanned Breakdowns.
Teams must update their activity boards regularly and monitor the trend of their graphs. These will
serve as evidence of their accomplishment in successfully completing their Phase 1 activities on their
Pilot Equipment.
Planned Maintenance Activity Board

PM Phase 0 Implementation
Step 0 Forms
- Inventory
- Headcount
- Ranking Etc
PM Vision
and
Mission
1
Pilot Machine
Photo and
PMUpdated
Pilot Team
Maintenance
Picture
Headcount
3
MTBF/BDO
Analysis Trend
Chart
BDO GRAPH
(Shows result
on Step 1 to 3)
BDO Chart
15
14
Phase 1
Teams Trainings
undertaken and
PM Minutes of
the meeting
4
Phase 2
10
Good to Find
and One Point
Lessons
Generated
11
Why-Why
Analysis for
Recurring
Deterioration
Lists of
deteriorations
restored
MP Design
Improvements
PM Before and
After for the
Pilot Machines
9
Equipments
Sectionalized
Drawings
Step 1 to 3
Roadmap
Plan vs Actual
PM Inspection
Standards
Generated
12
Horizontal
Replication and
Planning for
Fan-Out
13
Other PM
Activities
Completed
S3-14
3 Ring Binder for Step Activities already completed for PM Pilot
Note : Number represents the flow of presentation

Recommended 4 ft by 8 ft White board
26
Figure 3.2

3.9 Performing The Planned Maintenance Audit
Audits are done to check that the team comply with the activities performed in doing Planned Maintenance.
This is initially done by the TPM Facilitator together with the Maintenance Managers, while after exposing
the Maintenance Managers to such activities, they must own the audit themselves, since they are directly
responsible for the equipments. The Planned Maintenance Facilitator briefs the Maintenance Manager
on what to look for regarding audit, likewise the reason why they are the best candidate to perform the
Audit themselves. The Planned Maintenance Audit composed of 2 parts :
Room Audit or Activity Board Audit

Team present their activities to the auditors, referring to figure 3.2 on page 22 each number corresponds
to the sequence of activities they are going to present from Phase 0 to Phase 1 activities. Pilot team
explains in details of their accomplishment. Team must be brief and precise in their presentation and
this usually take around from 30 min to 45 min. Complete lists of Phase 1 audit is included in the appendix.
These are the maintenance indices that must take place if the team are ready for the audit
BDO (Breakdown Occurrence Trend) The Lower the better
MTBF (Mean Time Between Failure Trend) The Higher the better
The objective of the audit taking place and the auditor being their Maintenance Manager, is to see to it
that the team takes pride in their success on improving the breakdown rate of their equipment. If this
was possibly done on their pilot and worst equipment, then it can be done on all Rank A and B machines.
Equipment Audit
After the room or activity board audit, both PM auditor and the team proceed with the equipment and
auditor checks the validity of the documents with respect to the actual condition of the equipment. They
also looked for other unwanted factors and may include them in their pending requirements if found.
managers performing the audit asked the teams the benefits of performing Planned Maintenance and
how they are going to sustain whatever activities they had performed specially on restoration so as not
to let the equipment deteriorate and left unattended again. It is important that standards set forth
must be performed as this will serve as their sustenance measures, otherwise if these will be just for
show-off purposes, a couple of months work will bring back again the equipment to the stage where they
had started. Do not skip this very important factor, sustaining equipment must be done at all measures.
After several question and answer on the part of the team and the PM Auditors, the audit is concluded
And the team are graded for their performance, if the team had attain the standards and requirements
Set forth in their Phase 1 activities, then they deserve a passing mark which is usually a rating of 85%
or higher. If many items that must be addressed are found by the auditors, team may achieve a remark
of unconditionally passed unless otherwise all pending requirements are settled on the date both agreed
by the auditor and the team. Phase 1 audit compose of the following :
Preparatory Stage Completion of Phase 0 activities, how pilot machine is selected, training completion
Understanding of Current Condition
Restoration Activities and Completion
Rootcause Analysis and Countermeasure to prevent recurrence of the problem
Evidence of Before and After Restoration Trend in BDO and MTBF
Documentation and Sustaining Measures
27

3.10 Horizontal Replication or Fan-Out Activities
Depending on the number of equipments to be replicated or fan-out, the original Phase 1 team members
break themselves into several groups and perform Phase 1 activities to similar equipments. Since the
original member had already gain some experience in performing Phase 1 activities, he/she is responsible
In coaching new members on the activities to be performed.
PM Fan-Out Team 1
PM Fan-Out Team 2
PM Fan-Out Team 3
Figure 3.3
Original New Members

Member

Member

Member
3.11 Summarizing Phase 1 Activities

Activity
1.Categorize and Track Down BDO

of Pilot Machine
2. Perform Initial Cleaning on Pilot
3. List all deteriorations uncovered
and perform restoration
4. Sectionalize the machine into
different sub-assemblies and draw
5. Analyze deteriorations and prepare
Why-why Analysis
6. Set countermeasures for preventing
recurrence of the problem
7. Select worst sub-assembly and
perform restoration on equipment
8. Perform Steps 5 to 7 on other
sub-assemblies
9. Document Evidence on Before and
After Restoration
10. Classify Top Deteriorations and
prepare GTF or OPL
Table 3.1a
28

Continuation . . .
Activity
11. Update MTBF/BDO Trend

Chart for Pilot Machine
12. Summarize lists of deteriorations
for possible replication
13. Prepare Tentative Inspection
Standards and Update Checklists
14. Post all documents on Activity
Board and update regularly
15. Final Checking on completeness
of Activity and Documentation
16. Proceed with Phase 1 Audit
Phase 1 Activities for Horizontally Replicated or Fan-Out Equipments

Activity
Table 3.1b
1. Group the machine by batches

and backtrack BDO Data
2. Divide the original team and
add 2 new members per batch
3. Perform Initial Cleaning and
lists deteriorations uncovered
4. Check Pilots Horizontal
Replication and add new
deteriorations found
5. Perform Restoration on Fan-Out
or Replicated Machines
6. Update MTBF trend for Fan-Out
after completing restoration
7. Perform Inspection Standards
and add lists on Pilot Standards
8. Documentation and Posting on
Pilots Activity Board
Table 3.2
29

3.12 Phase 1 Completion
Phase 1 activities usually takes around 3 to 4 months to complete, and once this is done according to
the step activities provided, unplanned breakdowns can be dramatically reduced as high as 80 %, and
we have just perform the basics. Model equipment chosen must belong to the Rank A category and
fan-out or similar equipments must belong to both Rank A and B category.
Once breakdowns had been reduced on the 1st Pilot Equipment and their corresponding fan-out, carry
on the activities to other Rank A equipments and perform the same activities as you did in your 1st pilot
which can compose of different team. And update timeframe of completion on your Master Plan.
As each equipment had completely undergone Phase 1 activities, a reduction in breakdown is achieved.
Breakdowns which can stop and hurt your operations, and a change of mindset had undergone for the
team and the way they treat and maintain their equipments. Their skills had been upgraded since they
study and analyze each deterioration and why it occurred in their equipments, and this is an important
change in their daily tasks, what is important is that these becomes a habit. The team that had undergone these activities realized that the most important part of their job is not how many failures or breakdowns they had repaired for a given day, but how these breakdowns can be eliminated by a thorough
analysis of the failure that occurred.
Phase 1 is not only about improving the equipment, but it is also about improving the way operators and
maintenance think about their equipment. Just as each person needs love and care, equipments are
not exempted, if properly operated and maintained, they will deliver to perform the task required of them.
It is a good gesture for the maintenance manager to provide simple and inexpensive recognition to the
Team since they are proud of their accomplishments. A certificate of achievement can be provided by
HRD with your recommendation, or a simple lunch with the team may do. This is important in letting
them know you are acknowledging their efforts and improve your relationship.
The team that comprises the 1st pilot will serve as a model of success to every new team that will be
doing the same activities, they will be benchmarked and consulted by other teams in their activities
on Planned Maintenance. As more and more teams are created, more and more breakdowns are
reduced, maintenance skills are upgraded.
With the completion of the 1st Pilot Equipment on its Phase 1 activities, team can prepare to advance to
Phase 2 and must attend necessary training requirements provided by the PM Facilitator.
25
C hapter 4
Phase 2 : Lengthening Equipment Lifetime
4 Phase 2 : Lengthening Equipment Lifetime

4.1 Equipment Design Weaknesses
After completing Phase 1, it is important that Basic Equipment Condition must be maintained.
Maintenance teams observed a reduction in unplanned breakdowns but still we need to observed what
Part or spare is often replaced or worn out easily. Even if this is what is expected on the timely
replacement of the said part. Our objective in Phase 2 is to identify what parts needs to be improved in
terms of lifespan. Once the spare part with inherent design weakness had been identified, the team
Analyze and study the part and what need to be change, factors such as changing its dimension,
material change, or completely redesigning the part in order to increase its lifespan. Figure below
Details what we want to achieve in Phase 2 of Planned Maintenance.
4.2 From Natural To Extending Equipments Parts Lifespan
DETERIORATION
Extended Lifespan
Natural
Deterioration
Point 4
Point 1
Figure 3.1
Point 2
Point 3
Failure
Line
TIME
Time-Based
Condition-Based
Failed State / Run To Fail
26
Phase 1
ADDRESS BASIC
PROBLEMS
RESPONSIBILITIES
Equipment Inventory
Equipment Ranking
Pilot Machine Selection
Conduct Initial Cleaning
Basic Restoration
Reduce Breakdowns
Improve MTBF
Horizontal Replication
Stabilize MTBF
TASKFORCE
RESTORATION TEAM
Phase 2 - 3
Determine the
Maintenance tasks
required
Phase 4
Lengthen Equipment
Life & address difficult
minor stoppages
PM SYSTEMS
RCM MAINTENANCE
TEAM
RESPONSIBILITIES
Conduct an RCM approach
on determining the correct
maintenance tasks for the
worst equipment
To compose of maintenance
personnel with the most
comprehensive experience
of the equipments
PM IMPROVEMENTS
RESPONSIBILITIES
Address Design Weakness
Improve Set-Up Time
Improve Difficult Minor Stops
and other equipment
PM KAIZEN TEAM
Although JIPM procedures teach that each Step or Phase be done in sequence and on the same machine
with the same team involved. Whatever course of action in your maintenance organization you will undergo,
take note that it shall be the responsibility of the maintenance manager to consistently review the process
each team undergoes

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Planned M aintenance

Gearing Towards A Pro-Active Maintenance System

Understanding the Need For A Planned Maintenance System

2 Phase 0 : Understanding The Need For A Planned Maintenance System

Build Up A Planned Maintenance Organization In Your Company

3 Phase 1 : Stabilize MTBF Through Restoration

The Need for Restoration

4 Phase 2 and 3 : Establishing a Maintenance System

4 Phase 4 : Lengthening Equipment Lifetime

Addressing Equipment Weaknesses through Improvement

I Introduction on Planned Maintenance

I Introduction on Planned Maintenance

1.2 Planned Maintenance Defined

1.3 What Planned Maintenance Pillar Includes

I Introduction on Planned Maintenance

I Introduction on Planned Maintenance

Tips on Shortening Internal Set-Up Time

I Introduction on Planned Maintenance

Idling and Minor Stoppages

Design Speed Loss

I Introduction on Planned Maintenance

Defect and Rework Loss

I Introduction on Planned Maintenance

Design Speed Loss

Indices / Measurement to Use

Overall Equipment Effectiveness

I Introduction on Planned Maintenance

From the book of

I Introduction on Planned Maintenance

1.6 Different Approaches on Planned Maintenance

Reference : TPM Industries by Tokutaro Suzuki

Reference : Nissan Motor Co., Ltd, Yokohama Plant

Reference : Idemetsu Kosan Co,. Ltd. Hokkaido Refinery

Reference : Harris Kuala Lumpur, Malaysia, Assembly and Test Operations

Breakdown Maintenance and Time-Based Maintenance

I Introduction on Planned Maintenance

Reference : As per my previous employment and JIPM Consultant

Reference : Maintenance Consultant, Chairman of Studio Base Group

I Introduction on Planned Maintenance

1.7 What Planned Maintenance Wants To Achieve

I Introduction on Planned Maintenance

1.7 Planned Maintenance in 4 Phases

I Introduction on Planned Maintenance

Phase 3 : Periodically Restore Deterioration

Phase 4 : Predict Equipment Life

2 Phase 0 : Understanding The Need For A Planned Maintenance System

2.1 Building Your Planned Maintenance Organizational Structure

Top Maintenance Head

2.2 Planned Maintenance Kick-Off

2.3 Define Roles and Responsibilities

2 Phase 0 : Understanding The Need For A Planned Maintenance System

Roles and Responsibilities Of Top Maintenance Manager

Roles and Responsibilities Of Planned Maintenance Facilitator

Roles and Responsibilities Of Maintenance Managers

Roles and Responsibilities Of Maintenance Pilot Teams

2 Phase 0 : Understanding The Need For A Planned Maintenance System

2.5 Generate The Planned Maintenance Master Plan

SAMPLE - PLANNED MAINTENANCE MASTER PLAN