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Predictive Maintenance activities - Please review my proposed form/criteria

Laura Halleck

Starting to get Involved
#1
My company has recently been through our ISO / TS 16949 transition audit (from QS9000) and had a minor finding for not having evidence of predictive maintenance being done.

We were aware of this gap and had been struggling with how to apply predictive maintenance to our equipment since the typical techniques (vibration analysis, ultrasound, oil analysis, wear-particle analysis, thermography) do not apply or we do not want to spend the money on the equipment or outside service that would be required.

Here is the list that we have now come up with. Please review and provide me with any comments or suggestions you might have. This is our first attempt at applying predictive maintenance and we have no experts in this area.

Equipment 1:
- Check Auger ID / Bore OD of cartridge assembly:
Currently performed as an annual PM task. Will be modified to include measurement and recording of diameters on 3 cartridge assemblies and comparing against min / max limits on a quarterly basis. If diameters go outside of limits, the cartridge assembly will be replaced or adjusted.

Equipment 2:
- Check / adjust blade setting:
Currently performed as monthly PM. Will be modified to include measurement and recording of blade height and comparing against min / max limits on monthly basis. Will be adjusted if outside min / max levels.
- Check / Adjust Head Assembly:
Currently performed as semi-annual service contract PM. Will be modified to include check and record characteristic and condition at which an adjustment would be made by field technician.

Equipment 3:
- Inspect tools:
Currently performed as weekly PM. The machine includes self-monitoring software which will notify the operator if a vacuum loss has occurred in a tool (indication of wear or damage). If the operator is notified of such a vacuum loss, they will inspect the pick up tool in question for wear or damage.

- Check / Adjust strain gauge:
Not currently performed as PM. The machine includes self-monitoring software which will notify the operator if the measured force is outside of the limits. If the operator is notified of such a condition, they will notify the process engineer to adjust the strain gauge to be within the operating window.

Equipment 4:
- Check / replace tool
Not currently performed as PM. Tools may be replaced anywhere between 2.5 to 8 days. Operators will visually evaluate output condition and compare against visual aid twice daily (during regular SPC activity). When output condition matches visual aid, tool is replaced. Will collect information on visual condition in SPC form.

- Check cable:
Currently performed as semi-annual PM by field service technician. Will modify to include watching for a particular indicator to light while processing the SPC units (twice per day) to make sure it is lighting up during the process(cable is connected). Add check box to SPC form to check off that the light was checked. If the light does not fire, the cable will be checked for proper connection.

- Check output force:
Not currently performed as PM, but performed occasionally by process technician. Run force gauge check routine at start of shift and record force in SPC form; compare against min / max limits. If outside of limits, adjust force.

- Check workstage heaters; replace as required
Not currently performed as PM. Pre-heat first piece (start of shift) on workstage and take surface temperature with thermal probe, record in SPC form; compare against min / max limits. if outside of limits, replace heater.

Thanks for your time in reading through all this.
 
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2

2.5bostons

#2
Good start

Hi... probably more questions than answers, but willing to help you:)

Do you have any downtime logs or repair logs you can trend out specific repairs?

How often are you planning to do PM?

Weekly? Monthly?

What will be your sustain methodology? How will you track your progress for effectiveness? I.E. when the auditors ask about your program, what will you show for opportunities of improvement

Do you have any other lean activities or continuous improvement initiatives in place?
 
C

ChuckHughes

#3
Comments of predictive maintenance

Some thoughts:

The distinction between predictive maintenance and preventive maintenance is the signal that tells you to perform maintenance. Preventive maintenance programs are all based on a clock-calendar signal. "Its Tuesday, it must be oil change day".

Predictive maintenance programs are based on a signal that related to the eventual destruction of the equipment. Oil drop analysis of a hydraulic system tells you the degree to which the system is in need of some maintenance. Vibration analysis tells you to what extent the source of the vibration is loose, out of lubrication, or starting to destroy the races/rollers. 1 million strokes on a punch die will create wear lands in excess of acceptable levels.

A program of preventive maintenance needs only a calendar. Predictive maintenance needs more complex and varied signal sources and a way to capture the signals.

You have the start to a predictive program, however you have to set the acceptable limits for your signals not your results like hole diameter. When will you change drills or blades or tool points so that you don't make bad parts? Some study is needed to see what the average wear rates are, etc.

I have seen a very clever use of SPC in monitoring amp draw on a screw machine that produces common parts almost continuously. The repeated patterns of amp draw over the cycle of machining the part are plotted and as tool points wear (and cause higher than normal readings) or points break off (and cause lower than normal reading at the start of the cycle) the machine shuts down. You can tell if the metal is harder or thicker that normal with this monitoring program also. Pretty slick.. stops when one part is bad.
 

Helmut Jilling

Auditor / Consultant
#4
lhalleck said:
My company has recently been through our ISO / TS 16949 transition audit (from QS9000) and had a minor finding for not having evidence of predictive maintenance being done.

We were aware of this gap and had been struggling with how to apply predictive maintenance to our equipment since the typical techniques (vibration analysis, ultrasound, oil analysis, wear-particle analysis, thermography) do not apply or we do not want to spend the money on the equipment or outside service that would be required.

Here is the list that we have now come up with. Please review and provide me with any comments or suggestions you might have. This is our first attempt at applying predictive maintenance and we have no experts in this area.

Equipment 1:
- Check Auger ID / Bore OD of cartridge assembly:
Currently performed as an annual PM task. Will be modified to include measurement and recording of diameters on 3 cartridge assemblies and comparing against min / max limits on a quarterly basis. If diameters go outside of limits, the cartridge assembly will be replaced or adjusted.

Equipment 3:
- Inspect tools:
Currently performed as weekly PM. The machine includes self-monitoring software which will notify the operator if a vacuum loss has occurred in a tool (indication of wear or damage). If the operator is notified of such a vacuum loss, they will inspect the pick up tool in question for wear or damage.

- Check / Adjust strain gauge:
Not currently performed as PM. The machine includes self-monitoring software which will notify the operator if the measured force is outside of the limits. If the operator is notified of such a condition, they will notify the process engineer to adjust the strain gauge to be within the operating window.

Chuck Hughes gave a good working definition of Predictive and Preventive Maintenance.

From my quick read, items 1 and 3 sound like predictive types of maintenance. I don't believe that either QS or TS is nitpicky about the particular definition, but simply want to drive your thinking in how you apply maintenance beyond jsut fundamental PM stuff, to a level where maintenance as a process improves overall process performance.

I suspect they were influenced by TPM principles when they wrote this section. (By the way, this was a QS requirement as well.)
 

Laura Halleck

Starting to get Involved
#5
Thanks for all your replies.

Hi All,

Thank you so much for taking the time to read through my long post and replying to me.

Here's some answers to your questions...

2.5 bostons:
We have downtime logs, but just implemented them last month (mid-April - about 2 weeks before our audit). We did review them as we developed this list. One of the items on the list is based on this review. The other downtime issues were determined to be random in nature or not something we could have predicted before failure.

Depending on the equipment and type of maintenance, we do PM weekly, monthly, quarterly, semi-annually, and annually. In the descriptions, I listed the frequencies these things were being done as regular PM.

As far as the sustaining methodolody is concerned, I would be insterested in hearing your suggestions about this as well. This is where we've had problems in the past.

For effectiveness, we plan to review our downtime logs on a monthly basis against our current PM plan to see if modifications need to be made to the plan. Beside for tracking uptime percentages and on time delivery, I'm not sure what other metrics to use for effectiveness.

We use Six Sigma & Lean as continuous improvement methodologies. I'd be interested in hearing any suggestions for how to tie that in to the PM program.

ChuckHughes:
I'm guessing that you're referring to the diameter measurements for equipment 1. This is actually a tool (dispenser) that wears over time, thereby enlarging the space between the inner part and outer part and reducing the effectiveness of the tool. Right now, we only check this on a yearly basis and don't record the data. We are hoping that this will help us to change out these tools before the tool fails. This seems in line with your description of predictive maintenance.

hjilling:
I know this was a QS requirement as well, but our auditor never held us to it in the past. We were always able to explain why it didn't apply to us and were left alone about it. Now, he wants it done.


Thanks again.
 
B

bgwiehle

#6
While reading through the list of maintenance activities, I wondered

- if the all the measuring equipment referenced (strain gauges, load cells, temperature probes, etc.) is included in your calibration system?
- if your control programs are self-checking (machine stops/ rejects all product, if the sensors fail or fail to cycle)?

While not applicable to your original question, addressing any gaps in these areas could also be helpful.

B.G. Wiehle
 

Helmut Jilling

Auditor / Consultant
#7
lhalleck said:
...predictive maintenance.

hjilling:
I know this was a QS requirement as well, but our auditor never held us to it in the past. We were always able to explain why it didn't apply to us and were left alone about it. Now, he wants it done.


Thanks again.

Yeah, well, ya can "pay me now or pay me later"...

My daughter sometimes wonders why I insist she get timely oil changes, since the car doesn't seem to run any better with or without the oil change, but this stuff matters.

Time to pay up...
 
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