The planned maintenance activity
The planned maintenance activity is the activity that the preservation
station of the specialty builds the system which maintains facilities deliberately.
The trouble factor of the facilities is including many things.Therefore,
the means which reduces trouble, too, isn't uniform.It tight does "the
autonomy maintenance activity" which maintains the basis use condition
of the facilities.
Then, the activity that the station of the professional maintenance does
"a corrective maintenance", "a preventive maintenance",
"the forecast maintenance" deliberately is necessary.Then, it
analyzes the trouble which occurs at present.Then, it takes measures to
prevent from the recurrence of the trouble by.
It is the basis which above activity makes reduce trouble to.Moreover,
it reflects the know-how which was born with these activities in the design
by the planning of the facilities.Then, it is necessary to implement early
stage flow control over the facilities.
To do above activities systematically is a planned maintenance activity.
| Step | The active name | The active contents |
| 1step | It corresponds to the autonomy maintenance activity and it implements the check of the facilities. |
･ It corresponds to the autonomy maintenance activity and it checks
facilities generally in the point of view of the professional maintenance. It checks "the lubrication, the oil and air pressure, the drive, the electric control". ･ It decides the control item and the par of the plan maintenance activity. ･ It puts the rank (A,B,C) of the importance to the facilities. ･ It sets the definition of the facility trouble. ･ The control over the trouble of the preservation restoration and the manufacturing restoration, dividing it ･ It installs a plan maintenance activity board. |
| 2step | The trouble analysis and the recurrence prevention | ･ It studies a way of analyzing trouble. ･ It orders the record of trouble "the facilities, the mold" which happened in 1 year of the pasts in the factory.Then, it orders according to "the number of the trouble", "the facility stop time", "the phenomenon", "the disposal", "the cause". ･ It reconsiders the record form of the trouble.(Trouble analysis-the form that the analysis can write why why) ･ It implements a trouble analysis from model facility "(the A rank)". ･ After trouble analysis, it does the measure which prevents the recurrence of the trouble, analyzing with the recurrence prevention chart. |
| 3step | ･ The making of a check, a maintenance, a standard | ･ It orders the activity of 1-2 steps. ･ It enters item "(the forecast, the prevention, the improvement)" of the recurrence prevention of the trouble in "the lubricating check maintenance standard" of each of the autonomy maintenance and the professional maintenance. Then, after checking with "the cleaning lubricating check standard" which was made with the autonomy maintenance activity 3 step, it makes "the check, the serviceable standard" of the professional maintenance. ･ Based on the check maintenance standard, it makes a month preservation calendar with the year preservation calendar. ･ It digs up the past and an estimate failure mode. |
| 4step | "Spare control" "The control of drawings" "The lubrication control" "The maintenance information control" |
･ It arranges existing spare, ordering and it makes a spare list. ･ It reconsiders the ordering system of the spare. ･ It arranges a facility treatment manual and a drawing, ordering. ･ It investigates the kind and the busy condition of "the lubrication and operation oil" and it makes a list. It reconsiders the unification of the kind of oil and a replenishment method. ・Moreover, it arranges an oil station. ･ It builds a personal computer input system in "the preservation record, the man-day, the occurrence expense, the schedule maintenance calendar". (Or, it reconsiders a system) |
| 5step | The diagnosis introduction of technique of the facilities The introduction of technique of the recycling repair |
･ It studies the diagnosis technique of the facilities.･ It participates
in the study and training seminar of the facility diagnosis technique. ・Then, it introduces diagnosis equipment. ･ "The vibration diagnosis, the effective electric power examination, the displacement examination, the oil examination" The others ･ The effective electric power diagnostics (the ell fy) is a very effective way of the diagnosis. ･ The introduction of the recycling repair (The metal fusion weld equipment) ･ It implements facility remodeling. |
[Facility breakdown and the breakdown
classification]
It is as follows according to the definition with the breakdown. "The
facility equipment, the part and so on lose the function of the rule with
the breakdown".That is, it is in the condition that to work became
normally in the function of the facilities to have.
It is classified as follows by the phenomenon of the breakdown.
① The stall-type breakdown
This is breakdown with the function which has stopped suddenly while
the facilities operate.
② The depression-type breakdown
This is breakdown with the that there is to do gradually many manufacture
bad and becoming process capability of which the facilities can operate
but it declines.Or, it is breakdown with the declining speed of the manufacture
carriage.
It is as follows when classifying in the occurrence form of the breakdown.
① The suddenly happening breakdown
It is the breakdown which occurs suddenly while operating without estimating
at all. Then, the restoration takes time and it obstructs a production
activities. That is, it is the breakdown which becomes the obstruction
stop of the time operating rate in the facility overall efficiency. The
schedule maintenance and in the autonomy maintenance activity, the important
thing is to reduce this suddenly happening breakdown first.
② The estimated breakdown (The forecast breakdown)
The breakdown to have discovered a malfunction daily in the check and
by in the fixed period facility examination, it did a deliberate restoration
repair in the holiday and for it not to have given the production obstruction
However, this changes to resulting in breakdown with the degradation and
there is not it. It is possible to say the trouble which restored before
becoming happening breakdown suddenly. The activity of "Yellow card"
to implement by the autonomy maintenance activity is the activity that
will catch the abnormality of the facilities before becoming happening
breakdown suddenly.
If the happening breakdown reduces substantially suddenly, next, the reduction
of this estimate breakdown must be implemented.
It depends and the writer is guiding to count a number tight about this
estimate breakdown, too, and to implement a breakdown analysis.
Also, it is as follows when classifying from the used hours elapse
of the facilities.
① The early stage-type breakdown
he breakdown which occurs with doing design worse, manufacturing worse's,
constructiveness bad and so on in case of test run beginning of the facilities
② The occurring-type breakdown
The breakdown which occurs accidentally in the extraordinary stress and
the degradation phenomenon in the early stage after entering stable operation
Also, there is breakdown which occurs in case of stable operation without
early stage-type breakdown measure's being sufficiently struck, too.
③ The aging-type breakdown
The breakdown of which the chemical degradation such as the weariness of
each part, the mechanical degradation and the oxidation, the corrosion
such as the abrasion moves ahead with the long-range operation and it occurs
by the factor
When classifying from the factor of the breakdown
① The design bad type breakdown and the manufacturing construction bad type breakdown
The design bad type breakdown which occurs in the leading, not resulting
in the degradation, but with part itself not doing normal operation in
the mistake in case of design and lacking in the strength
Or, it is the manufacturing construction bad type breakdown which occurs
in the leading with the precision not going out of the part manufacturing
and the mistake at the time of the construction and lacking in the strength.
It is the trouble that the great part of the early stage-type breakdown
is this type.
② The stress degradation type breakdown
The breakdown which occurs with the degradation such as operating stress "the abrasion, the nibble, the loosening, the damaging, the stretch, the crack, the oxidation, the corrosion, the heat expansion ," with all kinds
③ The operation bad type breakdown
This is the breakdown which is caused by the operation mistake of the operator.
These are the breakdown that the extraordinary operation which originates
in the the right way of operating and plan, adjustment knowledge lack becomes
cause.
[The reduction of the facility breakdown]
The breakdown factor of the facilities is including many things as the
preceding clause classifies breakdown. It depends and the means which reduces
breakdown, too, isn't uniform.
The three-basis pillar of the breakdown reduction is as follows.
1. The autonomy maintenance activity which does the right operation
operation of the facilities, and cleaning, refueling, a check
2. The activity of the schedule maintenance by the professional
maintenance subdivision (The preventive maintenance and the forecast preservation
and the corrective maintenance)
3. Then, it is the activity to prevent from recurrence by analyzing
the breakdown which occurs at present by.
Moreover, it is necessary to reflect the know-how which was born with these
activities in the facility design.
To do above activity systematically makes breakdown reduce.
[The analysis of the facility breakdown]
As for being restoring breakdown without analyzing the cause of the facility
breakdown accurately, the breakdown by the cause always recurs. Also, a
measure to the similar facilities isn't made. Moreover, it isn't possible
to reflect (the MP information) to the new plan facilities.
The breakdown except the early failure by doing design bad and doing the
bad of the construction becomes the stress which is always. It analyzes
the cause of the stress and it excludes and it reduces the stress. Or,
the measure to make strong in the stress is necessary.
Of the way of finding out the cause of the actually occurring breakdown
by the facility breakdown analysis Moreover, the breakdown doesn't occur
in the past, but it digs up the breakdown which is expected in future and
there is a way of analyzing in what cause they occur.
It writes down to this place actually about the way of analyzing occurring
breakdown.
① It is a way of analyzing breakdown why why (The single cause analysis).
This is the breakdown analysis of the stall and the outbreak. It is
the analysis which arrives at the occurrence cause of the stress last,
running down with why about why it occurred from the phenomenon of the
breakdown and why it became it so. However, when the principle general
rule of the knowledge and the manufacture, the carriage of the function
structure of the facilities and so on isn't understood, the analysis sometimes
comes to a deadlock why why on the way.
To study knowledge having to do with function structure, and being physical
and being chemical why why in parallel in case of the implementation of
the analysis is important. The analysis technique of the trouble physics
becomes necessary to the investigation of the trouble part.
The recurrence prevention does the measure of the restoration and the improvement
to the stress cause which was why won in the trouble analysis why.
② The way of analyzing a PM and analyzing an FTA (The compound cause
analysis)
It is the trouble analysis of the depression and the minor key stop.
The breakdown of the compound factor has done a measure without finding
true cause. It depends and the repeat breakdown occurs and is often chronic-izing.
It does a PM analysis and an FTA analysis for these breakdown analyses.
The breakdown analysis that an analysis was why come to a deadlock why,
too, uses this way.
③ The way of analyzing common cause
This is different from the trouble analysis with the uniform of one. It
analyzes the occurrence condition of the breakdown, and a part, a phenomenon
and so on and it is the way of analyzing and doing a common measure in
the common phenomenon and the cause of the part.
[The recurrence prevention of
the breakdown]
For the recurrence prevention of the breakdown, prevent from the cause
from the breakdown analysis which occurred to the above-mentioned actuality,
recurring. Moreover, it analyzes the breakdown which is beforehand thought
of and there is a way of preventing the breakdown occurrence.
The mechanism which prevents either of trouble is the same.
It should use "the list the up and the preservation method setting
table of the breakdown which is thought of" and "the breakdown
recurrence prevention flow figure" of the writer contrivance.
It is necessary to implement a recurrence prevention measure surely based
on this "the breakdown recurrence prevention flow figure".
[Difference of the forecast maintenance
and the preventive maintenance]
The maintenance method which the schedule maintenance aims at is called
"the condition maintenance" (CBM).
However, all is always not a CBM from the process of the equipment. It
considers both of the social influence which the maintenance expense vs.
the effect and the breakdown exert and it chooses an appropriate maintenance
method.
However, it is an ideal if it is possible to make the CBM system which
doesn't spend money appropriately.
The basis of condition maintenance (CBM) is forecast maintenance and a
preventive maintenance. The forecast and the prevention are a three-legged
race and are to implement both preservation balance well.
The forecast maintenance is a check and an diagnosis. If comparing this
thing to the body of the person We check whether or not it is good or whether
or not it is bad in the physical condition in life in every day. hen, it
is that we receive a search by the fixed period medical. This is weight
measurement, blood pressure measurement, an electrocardiogram, a chest
X ray, eyesight ear measurement, blood and an urine analysis and so on.
It is the diagnosis whether or not the function of the body is normal or
whether or not it is extraordinary.
The preventive maintenance is right operation, cleaning, refueling, increasing
tightening-up, and so on. If comparing to the body of the person We are
that the life, the dormancy that the rule is right, the meal that the nutritional
balance came off, the exercise which is moderate, that the bathing moderate
is done, the cleaning of a tooth, the bathroom, the taste amusement exclude
a mental stress.
It is said to that the schedule maintenance needs facility diagnosis technique
simultaneously with introduction of the TPM. Then, it lies to the acquisition
of the diagnosis technique.Of course, this is a necessary thing.
However, however the degradation abnormality of the facilities can be forecast
in the discovery by the facility diagnosis, the degradation can not be
prevented. To prevent degradation, the preventive maintenance must be done.
Also, it is necessary to do together with the improvement maintenance to
make endure degradation.
[Phase of the forecast maintenance ]
Phase 1---
It is the forecast of the malfunction in the allophone, the vibration,
the generation of heat, the leakage by the five senses of the person and
so on.
Phase 2---
The forecast of the malfunction with the fixed period measurement by
the diagnosis equipment The vibration diagnosis, the effective electric
power diagnosis, the heat diagnosis, the displacement diagnosis, the pressure
diagnosis, the stress diagnosis, the insulation diagnosis, the operation
oil analysis and so on
Phase 3---
It forecasts by the automatic continuation facility diagnosis by the
on-line monitoring.
[The breakdown which can not be forecast
is a thoroughgoing preventive maintenance].
The breakdown of the mechanical system got for the degradation forecast
with being considerable in the recent facility diagnosis technique to be
possible. However, the failure mode the forecast about which is difficult
still is the extraordinarily depending trouble of the control circuit.
It is because a computer is controlled about most of the recent facilities
control. It depends and the following trouble occurs.
"Short circuit of the control basis circuit" "Doing insulation
bad" "The extraordinary noise" Being "the bug on the
program" and so on Especially, when becoming in the summertime, it
comes across the facilities to be cooling with the electric fan by opening
the door of the control board in the purpose to prevent these trouble.
There should be another of something which is strange cause in this. Because
it was scarce about the knowledge of the electric control, it taught the
professional of the acquaintance the following and the writer got.
It is as follows when ordering from getting in it.
[Trouble factor of the control error]
1) The short-circuiting of the basis circuit
It is the error of the cause which causes short-circuiting in the time
of the printed circuit of the basis and among the points of tact. It shows
the factor which causes short-circuiting by the following function expression.
The fine fine particle × humidity × temperature change on the basis,
the dewfall=the short-circuiting
It depends in hot and humid the summertime in Japan. and in the summertime,
it is easy to mistake with the equal sign high temperature. As for the
trouble of the control circuit, the humidity and the fine particle are
a problem.
2) The error by the high temperature of specific CPU･IC
There is it itself in the exothermic body and moreover CPU･IC with high
density is the trouble which happens with heat by fresh air in the control
board added.
3) The error by the noise
It is the trouble which happens to the control circuit with the approaching
by the noise from first power supply and the extraordinary electric noise
from the facilities around.
4) The error by the insertion connector part insulation of the basis
It is the error the vibration of the control board loosens the insertion
of the connector part of the basis and also which causes an insulation
phenomenon in the corrosion by the humidity fine particle and so on.
The trouble by above factor occurs without being able to be hardly forecast.
In this way, the trouble the forecast about which is difficult has no choice
but to implement a thoroughgoing preventive maintenance.
[Article 7 of the control board preventive maintenance]
1) The check and the maintenance of the control board fan cooler and the
sink filter …… factor The prevention of 1) and 2)
2) The control of the flow of fan air between the inside of the control
board and the basis …… factor The prevention of 1) and 2)
3) The exclusion of the humidity in the control board…… factor The prevention
of 1) and 4)
4) The closure and the shutting of the crack part of the control board……
factor The prevention of 1) and 4)
5) The fixed period wash by the control basis……… factor The prevention
of 1)
6) It insulates a control circuit part and first power supply circuit part.And,
it reconsiders the ground taking of the control circuit part. …… factor
The prevention of 3)
7) The removal of the vibration occurrence source to the control board……
factor The prevention of 4)
| Return |