We are implementing a preventive and predictive maintenance plan for our automotive product lines. I was wondering if anyone had any advice, or could point me towards a good source of information on procedures relating to 4.9.g.1

Thanks!

I agree with Marc. You will also want to include something on predictive maintenance. Do you do fluid checks or IR checks of heat-sensitive components? Do you track/ optimize up-time?

You're right, Roger - I forgot the predictive part of the requirement.

Main points:

You system can be centralized or distributed.

Set up a database (or other substitute such as a spreadsheet) and list your equipment and make a schedule (calendar) based upon it. Then follow the schedule.

You must have a list or procedure (criteria to act upon) for each piece of complex equipment. This can be the equipment manual or manufacturer's recommendation - but must be a document with criteria. Some folks categorize some equipment in a way where certain equipment gets a 'standard' PM.

You must have evidence that each PM is performed. If you miss or delay PMs, you must be ready to explain why and the effect upon your PM program and on the equipment.

Verifying/validating the PM system should be part of your internal audits.

You must show that you have critical parts available for critical manufacturing equipment and have a plan for breakdowns (ability to continue production). Be ready to explain your threshold for catastrophy vs normal (expected) failures: ie.: You cannot plan for everything but most you can plan for. Plan with respect to availability of parts from suppliers. Consideration of production schedule loading may be discussed.

There is software available.

[This message has been edited by Marc Smith (edited 11-11-98).]

Roger: Our compant is pursuing QS-9000 certification and would you pleasure to send me a procedure for PM?
TKS&B.RGDS!

Roger,

I would like one too, if possible!

Thanks,

Michael

why not add one to the pdf list...eh? I am sure marc would be happy to oblige if provided with one.

Mine are too company specific .... wouldn't help

Have any of you looked at TPM (Total Productive Maintenance)? This methodology is great for assuring that you have what you need with regard to Predictive and Preventive Maintenance. Marc has a string on TPM running, along with PDF files to download. Take a look. If you have other questions, let me know. I implemented a TPM system when I worked at Motorola.

Have any of you looked at TPM (Total Productive Maintenance)? This methodology is great for assuring that you have what you need with regard to Predictive and Preventive Maintenance. Marc has a string on TPM running, along with PDF files to download. Take a look. If you have other questions, let me know. I implemented a TPM system when I worked at Motorola.

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TPM definitely covers ISO/QS requirements. I think it's a great system to have in place. Can take a while to implement, but the output is worth it.

Marc,
I understand there is going to be some further clarification in the 3rd Revision of the QS-9000 standards in the area of preventive/predictive maintenance and repair parts. Also wanted to let everyone know that the surveillance auditors are really starting to key in on SPC type data, so any program you implement (Vibe, infrared, or lube analysis) should include provisions for trending and effectiveness. The ultimate goal for maintenance everywhere is to go from a preventive to a predictive scenario, thus eliminating uneccesary downtime and keeping customers happy. Unfortunately vendors supplying equipment and manpower for predictive maintenance will sell you any package they can. It depends on the tone of panic in your voice or how many action items you are faced with from the last audit. The key is to determine what works and doesn't work for you in your environment, but be ready to defend your decisions come audit time. Bottom line is protect the bottom line, thats what we all get paid for.

Could any one please explain about the predictive maintenance systems?

Tool wear - measure your tool wear and determine, before bad product is made, when a tool should be replaced.
Optimization of uptime - determine what your major sources of downtime are and have a program in place to eliminate those sources. This is actually a good area to use the TPM metrics.
Correlation of SPC to PMs - using control charts, see what effect your PMs are having on your SPC metrics.
Important chartacteristics of perishable tooling - determine what factors control the lifetime of your perishable tooling and minimize their effects. For example, if using a mill or drill, determine what type of cutting fluid used, whether one should use carbide or other materials for the mills/drills, etc.
Fluid analysis - if you using lubricants for a process, determine when they are breaking down so you can replace them before they cause a problem.
Infrared monitoring - for electronic circuits, use infrared scanners to determine "hot spots" of circuits before failure occurs.
Vibration analysis - using vibration sensors, look at items such as gear boxes for unusual vibration which may indicate that a part is becoming too loose and may fail soon.

I am sure there are other means of elaborating on this, but this is my best shot.

Any other Predictive Maintenance comments?

What about "Documenting, evaluating and improving maintenance objectives"
Has any one any suggestions on this

Handled this via monthly departmental meetings, and the corresponding minutes. Made maintenance objectives a regular agenda item, and then reflect the objectives, etc, in the minutes...the auidtors in our 3rd edition upgrade surveillance were interested in evidence of the objectives being finished. I managed to tie that in with continuous imoprovement objectives, example: machinery upgrades; etc.

Hope this helps

Bryon

Subject: Predictive Maintenance
Date: Tue, 27 Apr 1999 11:43:26 +0100
From: svante.johansson - ullman.se
To: qs9000 - quality.org

I have another current question, that I know a lot of companies are wondering about; Predictive maintenance.

QS-9000, third edition, 4.9.g.1, says you shall "develop an effective planned total preventive maintenance system. At a minimum, this system shall include: . . Predictive maintenance methods - These methods should include a review of appropriate items such as the manufacturer's recommendations, tool wear, optimization of uptime, correlation of SPC data to preventive maintenance activities, important characteristics of perishable tooling, fluid analysis, infrared monitoring of circuits and vibration analysis. . ."

That's what the book says. Doesn't sound that hard to fulfill. "Include a review of appropriate items such as...". Our Quality manual presently says:

"Predictive Maintenance In those cases where we discover abnormal variations in the process, for esample by analysis of X-R-diagrammes and/or by abnormal tool wear, this shall be considered for preventive maintenance."

Our company is not yet QS-9000 certified. In the audition, we got two nonconformances regarding this subject.

One because what is "abnormal variations in the process" isn't clearly described/controlled. The other because we couldn't show any plans for predictive maintenance on key equipment.

Our business is lathing. Our company doesn't use any vibration analysis tools, nor are we planning to get any. We use annual infrared monitoring on electric circuits, but this is not described in our quality system. We use SPC a lot. Of course we use the manufacturer's recommendations for preventive maintenance. Our idea of solving this nonconformance is to point out that SPC-data is a tool for predicting maintenance needs.

How can we handle this? What is our auditor asking us to do? How can we rephrase our quality system to conform to the standard? Do we need to change our maintenance routines?

I am VERY greatful for any hints you might give me. The standard is very brief in this subject, I think. And it is also connected to the company's maintenance strategy. Shouldn't really be controlled in the QS-9000 standard, in my opinion. Comments?

Svante Johansson

Torsten Ullman AB

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Subject: Re: Predictive Maintenance
Date: Tue, 27 Apr 1999 14:02:30 -0700
From: NJ Marinaro pyxis - ix.netcom.com
Organization: The PYXIS Group
To: svante.johansson - ullman.se

SPC for maintenance and Predictive Maintenance is good for the product, but I believe that the resultant information is historical. That is, something changed now what do I fix. You then go into Corrective Action (Maintenance) not necessarily preventive action.

"We use annual infrared monitoring on electric circuits, but this is not described in our quality system." Add it to your quality system.

"...we use the manufacturer's recommendations..." Add a pointer in your quality system.

I would recommend you look at several things and track them in a database with regard to maintenance. Among them are repair parts usage, maintenance intervals (machine name and number and category of what and when), up and down time, actual repair time, cost of maintenance per machine, and so on. By tracking these items you can begin to do an analysis of what changes relative to time or material processed.

-- Capt NJ Marinaro