P D M

Business Diagnostics Shri Swami Samartha 1

Shri Swami SamarthaShri Swami Samartha1010thth Oct 2006.Oct 2006.


Our Objective here:Our Objective here:

A A

collective thinking collective thinking onon

Predictive Predictive Maintenance:Maintenance:


My Objective here:My Objective here:

ToTo

Facilitate Facilitate collective thinking collective thinking


My RoleMy Role

A facilitator A facilitator of the of the brain storming brain storming process.process.


My Role :My Role :

To add a systems approach in your To add a systems approach in your analysis & thinkinganalysis & thinking

To capture your observations & To capture your observations & experience in the required templates experience in the required templates so that these could be better so that these could be better understoodunderstood


This has to be DoneThis has to be Done

..


MaintenanceMaintenance

What is maintenance ?What is maintenance ?


Types ofTypes of

BreakdownBreakdownPreventivePreventivePredictivePredictive


Breakdown:Breakdown:Activities in the equipment which are Activities in the equipment which are unplanned unexpected altogether.unplanned unexpected altogether.Preventive:Preventive:Activities in the equipment which are Activities in the equipment which are planned as per a decided frequencyplanned as per a decided frequency


PredictivePredictive

Predictive Maintenance is thePredictive Maintenance is thesource which gives inputs source which gives inputs

for the preventive maintenance.for the preventive maintenance.


Predictive Maintenance is thePredictive Maintenance is the

Thinking Thinking Whereas Whereas Preventive maintenance Preventive maintenance

is theis the

action on the thinking.action on the thinking.


Objective ?Objective ?

To be proactive and not reactive in the To be proactive and not reactive in the maintenancemaintenance

Reactive is after the event Reactive is after the event Proactive is before the eventProactive is before the event


Predictive Predictive

Take appropriate actions Take appropriate actions So as to avoid the probable breakdown So as to avoid the probable breakdown



Take appropriate actions based on the Take appropriate actions based on the abnormalitiesabnormalities observed in the observed in the designated parameters of any critical designated parameters of any critical equipmentequipmentSo as to improve the performanceSo as to improve the performance


AbnormalitiesAbnormalities

VibrationVibrationSoundSoundMotionMotionTemperatureTemperatureConsumptionConsumptionParameters of the productParameters of the product



Take preventive actions based on the Take preventive actions based on the observed variations observed in the observed variations observed in the selected parameters of any critical selected parameters of any critical equipmentequipmentSo as to improve the effectiveness & So as to improve the effectiveness & efficiency of that equipment.efficiency of that equipment.


Improve the performanceImprove the performance

Reduce the down timeReduce the down time



Improve the up timeImprove the up time



Improve the MTBFImprove the MTBFMean time between failuresMean time between failures



Reduce the MTTRReduce the MTTRMean time to repairMean time to repair


What is PDM ?What is PDM ?

Observation & AnalysisObservation & AnalysisIt’s a complete PDCA cycleIt’s a complete PDCA cyclePlan Do Check ActPlan Do Check Act


Plan Do Check ActPlan Do Check Act

Plan ( appropriate actions which shall Plan ( appropriate actions which shall arrest the root cause of the observed arrest the root cause of the observed variation )variation )Do (Carry out the required maintenance)Do (Carry out the required maintenance)Check ( Again observe the said Check ( Again observe the said

parameters)parameters)Act ( Is the variation reduced ?)Act ( Is the variation reduced ?)


DMAICDMAIC

D (Define)D (Define)M( Measure)M( Measure)A (Analyze)A (Analyze)I (Improve)I (Improve)C (Control)C (Control)


DMAICDMAIC

D Define what parameters are criticalD Define what parameters are criticalAlso define what is the critical value of Also define what is the critical value of

that parameter ?that parameter ?M( Measure on a routine basis)M( Measure on a routine basis)A (Analyze whenever there is a variation)A (Analyze whenever there is a variation)I (Improve …means act on the root cause)I (Improve …means act on the root cause)C (Control…sustain)C (Control…sustain)


Essence of PDM:Essence of PDM:

It is therefore clear that PDM is a dynamic It is therefore clear that PDM is a dynamic phase of observing & analysis.phase of observing & analysis.

The decided actions can be taken The decided actions can be taken during the planned maintenanceduring the planned maintenance


What inputs required ?What inputs required ?

Maintenance manuals Maintenance manuals History cardsHistory cardsExperience on that equipment:Experience on that equipment:Especially related to abnormal Especially related to abnormal behaviourbehaviourof that machine.of that machine.

P D M

Business

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