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7 Steps of planned Maintenance

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  1. Support & Guidance to ‘Autonomous Maintenance’ activities
  • Participate with operators in putting green & red tags
  • Attend red tag abnormalities
  1. Evaluation of Equipment failure/ breakdown status & understand the situation.
  • Do why-why analysis for repeated abnormalities, find & eliminate root cause.
  1. Reverse deterioration & correct weaknesses.
  • Extended help to operators to prepare ‘Tentative Standards’ for cleaning, Lubrication & Inspection.
  • Establish ‘TBM’ & ‘CBM’ based Maintenance schedules
  1. Build an ‘Information Management’ system.
  • Extend help to operators in education, on job training in general inspection & developing inspection procedures
  1. Build a ‘Periodic Maintenance’ system.
  • Prepare standard documents for material selection, expense estimation, spare part management, work safety standards, Lubrication classification etc.
  1. Build a ‘Predictive Maintenance’ system.
  • Introduce ‘Equipment Diagnostics’ technology
  • Develop Equipment diagnosis skills & change TBM in to CBM.
  1. Evaluate the planned Maintenance system.
  • Compare, review total system & strengthen weak points.
  • Consolidate planned Maintenance, prepare Master Plan.

Why – Why Analysis

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Acknowledgement: Japanese Institute of Plant Maintenance

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Author: Kaizen Institute - India!

Kaizen Institute – India is part of the Global Kaizen Institute operations. Kaizen Institute was established by Sensei Masaaki Imai, the GURU of Kaizen. He wrote the 1st book 28 yrs ago and that is when it all started . We operate in 30+ countries today and have over 400+ coaches helping more then 600 organizations Learn, Apply, Sustain – Kaizen/ Operational Excellence. In India we have two physical offices – Pune & Ahmedabad and 27 coaches in all.

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