tal Productive Maintenan

It can be considered as the medical science of machines. Total Productive Maintenance (TPM) is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to hold emergency and unscheduled maintenance to a minimum.

Why TPM ?
TPM was introduced to achieve the following objectives. The important ones are listed below. Avoid wastage in a quickly changing economic environment. Producing goods without reducing product quality. Reduce cost. Produce a low batch quantity at the earliest possible time. Goods send to the customers must be non defective.

TPM - History :
TPM is a innovative Japanese concept. The origin of TPM can be traced back to 1951 when preventive maintenance was introduced in Japan. Nippondenso was the first company to introduce plant wide preventive maintenance in 1960. Preventive maintenance is the concept wherein, operators produced goods using machines and the maintenance group was dedicated with work of maintaining those machines, however with the automation of Nippondenso, maintenance became a problem as more maintenance personnel were required. Thus Nippondenso which already followed preventive maintenance also added Autonomous maintenance done by production operators. The modifications were made or incorporated in new equipment. This lead to maintenance prevention. Thus preventive maintenance along with Maintenance prevention and Maintainability Improvement gave birth to Productive maintenance.

Structure for TPM

Implementation :

Pillars of TPM

5S
TPM starts with 5S. Problems cannot be clearly seen when the work place is unorganized. Cleaning and organizing the workplace helps the team to uncover problems. Making problems visible is the first step of improvement. Japanese Term Seiri Seiton Seiso Seiketsu Shitsuke English Organisation Translation Tidiness Cleaning Standardisation Discipline Equivalent 'S' term Sort Systematise Sweep Standardise Self - Discipline

Benefits of TPM
A Safer Workplace Associate Empowerment An Easier Workload Increased Production Fewer Defects Fewer Breakdowns Fewer Short Stoppages (Chokotei) Decreased Costs Decreased Waste (Muda)

OEE
OEE = A x PE x Q
A - Availability of the machine. Availability is proportion of time machine is actually available out of time it should be available. A = ( MTBF - MTTR ) / MTBF. MTBF - Mean Time Between Failures = ( Total Running Time ) / Number of Failures. MTTR - Mean Time To Repair. PE - Performance Efficiency. It is given by RE X SE. Rate efficiency (RE) : Actual average cycle time is slower than design cycle time because of jams, etc. Output is reduced because of jams Speed efficiency (SE) : Actual cycle time is slower than design cycle time machine output is reduced because it is running at reduced speed. Q - Refers to quality rate. Which is percentage of good parts out of total produced sometimes called "yield".

Steam Turbine

A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in 1884. It has almost completely replaced the reciprocating piston steam engine primarily because of its greater thermal efficiency and higher power-to-weight ratio. The steam turbine is a form of heat engine that derives much of its improvement in thermodynamic efficiency through the use of multiple stages in the expansion of the steam, which results in a closer approach to the ideal reversible process.

Turbine Operation
The steam turbine operates on basic principles of thermodynamics using the part of the Rankine cycle. Superheated vapor (or dry saturated vapor, depending on application) enters the turbine, after it having exited the boiler, at high temperature and high pressure. The high heat/pressure steam is converted into kinetic energy using a nozzle (a fixed nozzle in an impulse type turbine or the fixed blades in a reaction type turbine). Once the steam has exited the nozzle it is moving at high velocity and is sent to the blades of the turbine. A force is created on the blades due to the pressure of the vapor on the blades causing them to move. A generator or other such device can be placed on the shaft, and the energy that was in the vapor can now be stored and used.

Assuming there is no heat transfer to the surrounding environment and that the change in kinetic and potential energy is negligible when compared to the change in specific entropy we come up with the following equation

t is the rate at which work is developed per unit time is the rate of mass flow through the turbine

Turbine Arrangement

In most cases, steam turbines and the generators they drive are laid out in sequence, meaning that the casings and shafts of all of the turbine sections and generator are in a single line. This is referred to as a tandem compound layout or arrangement. In some cases, the casings and shafting are laid out with two parallel shafting arrangements. These are referred to as cross compound arrangement.

Steam Turbine Maintenance Frequencies and Tasks

Frequency Maintenance Task

Daily or Less 1. Conduct visual inspection of the unit for leaks (oil and steam), unusual Weekly or 1. Trend unit performance and health. Hand-held vibration noise/vibration, plugged filters or abnormal operation. Less readings non-return taken from the steam turbine and gearbox if 2. Cycle should be valves. oil and hydraulic fluid for water, Monthly or 1. Sample and analyze lube permanent vibration monitoring system is not installed. Less particulates, and backup and auxiliary lube oil pumps for proper 2. Test emergency Contaminants. operation. 2. Deferred weekly tests or valve cycling that experience . 3. Test the main lube oil tank and oil low pressure alarmshas indicated sufficient over speed trip if present. 4. Test the simulated reliability to defer them to or one month valve. 5. Cycle the main steam stop a throttle interval. 6. Cycle control valves if steam loads are unchanging. 7. Cycle extraction/admission valves if steam loads are unchanging.

Annually 1. Conduct visual inspection and functional testing of all stop, throttle, control, extraction and non-return valves including cams, rollers, bearings, rack and pinions, servomotors, and any other pertinent valves or devices for wear, damage, and/or leakage. 2. Conduct visual Inspection of seals, bearings, seal and lubrication systems (oil and hydraulic), and drain system piping and components for wear, leaks, vibration damage, plugged filters, and any other kinds of thermal or mechanical distress. 3. Conduct visual, mechanical, and electrical inspection of all instrumentation, protection, and control systems. Includes checking alarms, trips, filters, and backup lubrication and water cooling systems 4. Test the mechanical over speed for proper operation annually unless the primary system is electronic and has an OS test switch. For that system, electronic Over speed simulations should be conducted weekly while mechanical and electrical over speed tests should be conducted every 3 years. For electronic systems without an OS test switch, an over speed test should be conducted annually. 5. Conduct visual inspection of gearbox (if installed) teeth for unusual wear or

Failure mode , effects , and criticality analysis to a physical or procedural malfunction.

tep approach for identifying all possible failures in a desig

Basic terms

Failure "The LOSS of an intended function of a device under stated conditions. Failure mode "The manner by which a failure is observed; it generally describes the way the failure occurs. Failure effect Immediate consequences of a failure on operation, function or functionality, or status of some item

Indenture levels An identifier for item complexity. Complexity increases as levels are closer to one. Local effect The Failure effect as it applies to the item under analysis. Next higher level effect The Failure effect as it applies at the next higher indenture level. End effect The failure effect at the highest indenture level or total system. Failure cause Defects in design, process, quality, or part application, which are the underlying cause of the failure or which initiate a process which leads to failure. Severity "The consequences of a failure mode. Severity considers the worst potential consequence of a failure, determined by the degree of injury, property damage, or system damage that could ultimately occur."

Example FMEA Worksheet

Item / Potential Potential S Potential O Current Function Failure Effects of (severity Cause(s) (occurren controls mode Failure rating) ce rating) D CRIT RPN (risk Recomme Responsibility Action New S New O (detection (critical priority nded and target taken rating) characteri number) actions completion stic date New D New RPN

Fill tub High level sensor never trips

Liquid 8 spills on customer floor

level sensor failed level sensor disconnec ted

Fill timeout based on time to fill to low level sensor

80

Perform Jane Doe cost 10-June-2011 analysis of adding additional sensor halfway between low and high level sensors

Step 1 : Occurrence
In this step it is necessary to look at the cause of a failure mode and the number of times it occurs. This can be done by looking at similar products or processes and the failure modes that have been documented for them. A failure mode is given an occurrence ranking (O), again 110 Rating 1 2/3 4/5/6 7/8 9/10 Meaning No effect Low (relatively few failures) Moderate (occasional failures) High (repeated failures) Very high (failure is almost inevitable)

Step 2 : Sensitivity
Determine all failure modes based on the functional requirements and their effects. Determine all failure modes based on the functional requirements and their effects. A failure mode in one component can lead to a failure mode in another component, therefore each failure mode should be listed in technical terms and for function. Hereafter the ultimate effect of each failure mode needs to be considered. Each effect is given a sensitivity number (S) from 1 (no danger) to 10 (critical).
Rating 1 2 3 4/5/6 7/8 9/10 Meaning No effect Very minor (only noticed by discriminating customers) Minor (affects very little of the system, noticed by average customer) Moderate (most customers are annoyed) High (causes a loss of primary function; customers are dissatisfied) Very high and hazardous (product becomes inoperative; customers angered; the failure may result unsafe operation and possible injury)

Step 3 : Detection
When appropriate actions are determined, it is necessary to test their efficiency. In addition, design verification is needed. The proper inspection methods need to be chosen. First, an engineer should look at the current controls of the system, that prevent failure modes from occurring or which detect the failure before it reaches the customer. Hereafter one should identify testing, analysis, monitoring and other techniques that can be or have been used on similar systems to detect failures. From these controls an engineer can learn how likely it is for a failure to be identified or detected. Each combination from the previous 2 steps receives a detection number (D). Rating 9/10 7/8 4/5/6 3 2 1 Very Low Moderate High remote to Almost certain absolute Meaning - most customers are uncertainty annoyed

isk Priority Number ( RPN

RPN play an important part in the choice of an action against failure modes. They are threshold values in the evaluation of these actions. After ranking the severity, occurrence and detect ability the RPN can be easily calculated by multiplying these three numbers: RPN = S O D

Severity Classification
1 2 3 4 5 6 7 8 9 10 Failure would cause no effect. Boarderline pass but still shippable. Redundant systems failed but tool still works. Would fail manufacturing testing but tool still functions with degraded performance. Tool / item inoperable with loss of primary function. No damage to other components on board. Failure can be easily fixed (for example, socketed DIP chips). Tool / item inoperable with loss of primary function. No damage to other components on board. Failure cannot be easily fixed (true if not field repairable). Tool / item inoperable, with loss of primary function. Probably cause damage to other components on board or system. Tool / item inoperable with loss of primary function. Probably scraping one or more PCBAs. severity ranking. A potential failure mode affecting safe tool operation and/or Very high involves noncompliance with government regulation with warning. Very high severity ranking when a potential failure mode affects safe tool operation and/or involves noncompliance with government regulation without warning.

Basic flow of risk - based inspection and maintenance procedure .

ent vent trees for steam turbine uni

Best Practices for Steam Turbine Maintenance and Operation

e proper steam quality is delivered to the tu r expansion compensation . y and exhaust line are sized properly . piping needs to be properly ed .

Auto nomous Maintenance

SHARED RESPONSIBILITY OF MAINTAINING BASIC CONDITIONS OF EQUIPMENT BETWEEN PRODUCTION AND MAINTENANCE
Daily / Time - Based Maintenance Cleaning Lubrication Tightening Daily inspection by using 5 SENSES Right operation , right adjustment , right setting

I operate, You fix. I operate, You Clean.

We are AlI responsible for Our equipment. We are AlI responsible for cleanliness of Our line.

3 Key Tools for Autonomous Maintenance

Key Concepts Key Concepts
Shop floor based Shop floor based activities activities Operator conducted Operator conducted Operator enhancing Operator enhancing Team activity Team activity Autonomous Management Autonomous Management TPM Foundation TPM Foundation Part of the job! ! Part of the job

3 Key Tools 3 Key Tools

nActivity Board nActivity Board nMeetings nMeetings nOne Point Lessons nOne Point Lessons

The 7 steps of Autonomous Maintenance

1.Initial Cleaning (Initial Inspection &
-Detect problems of lines and restore its original state . state. -Start managing the line autonomously . ( 5S, Minor Stops, Quality ) -Solve Sources of Contamination and Hard to Reach areas. (Cleaning, Inspection, Lubrication ) Lubrication) -Develop tentative standards for cleaning , lubrication and inspection . inspection. -Provide training on their equipments , products and materials, inspection skills and other AM skills. Develop a routine maintenance standard by operators Standardize routine operations related to workplace management such as quality inspection of products, life cycle of jigs, tools, set up operation and safety. Autonomous team working

Restoration) 2. Source of Contamination & Hard-to-Reach areas 3. Standards of Cleaning & Lubrication 4.General Inspection
5. 6.Autonomous Inspection 6. Standardize Autonomous Maintenance operations

3 Years

Planned Maintenance
Objectives Objectives ::
Increase Equipment Reliability and Production Up Increase Equipment Reliability and Production Up -Time Time Minimize the maintenance cost by Minimize the maintenance cost by 11 ) reducing breakdowns ) reducing breakdowns 22 ) development of efficient maintenance methods ) development of efficient maintenance methods

To clarify which parts and locations of which equipment should receive what type of maintenance and to implement it in a planned manner

Planned Maintenance 6 Steps

Step 1 : Evaluate Equipment and Understand Current Conditions Step 2 : Restore Deterioration and Correct 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 30

M. T. T. R

&

M . T . B . F CALCULATION MOD
Improvement of Maintenance Skills MTTR

Improvement PM - Main Activities of Equipment MTBF

M E A N

TI M E

B E T W E EN

F A I L U R E

M T B F =

( OPENING TIME STOPS TIME) STOPS NUMBER FOR FAILURE

ME A N

TI M E

TO

R E P A I R

M T T R =

SUM OF TIME STOPS FOR FAILURE STOPS NUMBER FOR FAILURE

* LAST GOOD PART/FIRST GOOD PART

31

eam Turbine Blading Failure Mechani

Failure Mechanism Corrosion Resultant Damage Extensive pitting of airfoils, shrouds, covers, blade root surfaces Cause(s) of Failure Chemical attack from corrosive elements in the steam provided to the turbine FMECA These problems can be mitigated by designs that prevent crevices, lower stresses, and/or employ lowerstrength materials. It is also important to avoid unnecessary stresses and to maintain high-purity steam during operation.

eam Turbine Blading Failure Mechani

Failure Mechanism Erosion Resultant Damage Deformed parts subjected to steam temperatures in excess of design limits Cause(s) of Failure 1) Solid particle erosion from very fine debris and scale in the steam provided in the turbine 2) Water droplet erosion from steam which is transitioning from vapor to liquid phase in the flowpath FMECA Some protection against erosion-corrosion can be provided by low distribution ratio amines, which neutralize the acidity and elevate the pH of the condensate.

eam Turbine Blading Failure Mechani

Failure Resultant Damage Mechanism Creep Airfoils, shrouds, covers permanently deformed Cause(s) of Failure Deformed parts subjected to steam temperatures in excess of design limits FMECA On C.I. plate sleepers all keys should be driven in the direction of traffic on the double line and alternately in the opposite direction on single line.

eam Turbine Blading Failure Mechani

Failure Resultant Damage Mechanism Fatigue Cracks in airfoils, shrouds, covers, blade roots Cause(s) of Failure 1) Parts operated at a vibratory natural frequency 2) Loss of part dampening (cover, tie wire, etc.) 3) Exceeded part fatigue life design limit FMECA 1.Design to keep stress below threshold of fatigue limit (infinite lifetime concept); 2.Design (conservatively) for a fixed life after which the user is instructed to replace the part with a new one (a socalledlifedpart)

Benefits of FMECA
FMECA is one of the most important and most widely used tools of reliability analysis. The FMECA facilitates identification of potential design reliability problems FMECA helps
Identify possible failure modes and their effects Determine severity of each failure effect removing causes of failures developing systems that can mitigate the effects of failures.

to prioritize and focus on high-risk failures

The results of the FMECA

Rank each failure mode. Highlight single point failures requiring corrective action Identify reliability and safety critical components