IATF 16949 Cl. 8.5.1.5 - Requirement for Periodic Overhaul

[bkirch]

IATF 16949 section 8.5.1.5 (Total productive maintenance) has a requirement for periodic overhaul. We have a machining division in which overhauls really don't take place. Could anyone give me an example how they are going to meet this requirement if they find themselves in a similar situation?

Also, could anyone share how they plan to document their total productive maintenance system?

 

[Peters]

I have a problem with understanding this requirement (maybe problem with translation of the "overhaul").
What's the difference between maintenance plan (g), preventive maintenance (h) and periodic overhaul (j)? My understanding of the text: periodic overhaul is basic element of preventive maintenance and contained in maintenance plan. So why they used three separate clauses g, h and j? Second possibility - my understanding of "overhaul" is wrong...

 

[QualitySpirit]

You don't need to translate it. The definition is already in the section 3.

periodic overhaul
maintenance methodology to prevent a major unplanned breakdown where, based on fault or interruption history, a piece of equipment, or subsystem of the equipment, is proactively taken out of service and disassembled, repaired, parts replaced, reassembled, and then returned to service

 

[bkirch]

I completely missed that definition, but that is helpful. Could you give me an idea on what would be expected for evidence to show that we have a documented total productive maintenance system? Would a procedure be expected?

 

[ChuckHughes]

This is an interesting question that can be answered by "it depends on the situation".... Overhauling a machine is fundamentally an economic decision. I don't overhaul my pickup truck engine at 100K, although I could. The cost-benefit analysis may convince me that a new truck is warranted.
The need to "overhaul" equipment is usually based on the probability the machine will catastrophically fail in a manner that will require extensive repair and the event will be costly. Timing of overhauls (when to do them) is a major factor. Summer shutdown is used for these to avoid interruptions to production output.
I would not get wrapped up into what constitutes an overhaul vs annual maintenance event. I would concentrate on how you are able to prove the equipment is fit for service ( able to achieve the accuracy, precision, pace expected) once big changes are made to it.

 

[Jean-Paul Dosher]

Hello,

I´ve the same issue here. Wich methods or procedures i need for this process (periodic overall) ? I´ve set in my mind that periodic overall is already approached in TPM !

 

[Coury Ferguson]

Hello,

I´ve the same issue here. Wich methods or procedures i need for this process (periodic overall) ? I´ve set in my mind that periodic overall is already approached in TPM !

I would start with a Process Flowchart identifying when it would happen, or estimated to happen. Usually most large organizations have either a Summer Shutdown for a few weeks or a Christmas shutdown to manage the maintenance program. But, this is just what I have seen.

 

[Jean-Paul Dosher]

I would start with a Process Flowchart identifying when it would happen, or estimated to happen. Usually most large organizations have either a Summer Shutdown for a few weeks or a Christmas shutdown to manage the maintenance program. But, this is just what I have seen.

Thanks for the reply,

Usually we don´t have shutdowns, but anyway, i have to put it in my maintenance procedure. I think the inicial approach is get history (a year period), than identify and presume potential interventions.

 

[Coury Ferguson]

Thanks for the reply,

Usually we don´t have shutdowns, but anyway, i have to put it in my maintenance procedure. I think the inicial approach is get history (a year period), than identify and presume potential interventions.

Having history on the machines is always the best way. It will give you some data to determine when it is best to perform maintenance. 1 Year will give enough data to start, but in my opinion you would really need between 1 1/2 to 2 years data. You can also look at the provided maintenance handbook, to give you another idea when it would be best. Similar to your Car's Handbook with recommended services.

Just my opinion. I am not a specialist in machine maintenance so I maybe giving you some information you already know. Maybe even the wrong direction.

 

[Rameshwar25]

Periodic overhaul requires more time than normal breakdown. It is like refurbishment or renovation of machine. Generally, it is schedules based on:
1. Machine breakdown history data. If a machine breaks down frequently, MTBF is too low, then you can plan a periodic overhaul. You can link periodic overhaul requirement with MBTF hours.
2. As per recommendations of machine manufacturer, given in machine manual, it is planned after certain period of machine run.

RS