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What is Preventive Maintenance? | Predictive Maintenance |Types & Example

28/03/2024 by TECHIEQUALITY

What is Preventive Maintenance? | Predictive Maintenance |Types & Example:

Hi readers! Here, we are going to describe the concept of maintenance, types, examples, etc., basically, in this article, we will give more focus on what is preventive maintenance. Predictive maintenance and manufacturing examples and also on how to start a different type of maintenance activities in manufacturing industries. In manufacturing industries, we know very well how important the machine/ equipment’s condition get optimum productivity. Machines are subject to deterioration due to their use and exposure to environmental conditions. So, to maintain the machine condition we may need to carry out the maintenance of machines and equipment. The main purposes of maintenance are;

To keep the operation in an optimum working condition.
To increase the up-time of the machine.
Less expenditure on repairs.
To reduce the break-down percentage.
To reduce the MTTR Value and increase the MTBF value.
Lesser overtime pay for maintenance personnel.
Increases productivity and minimizes waste and increases the rate of quality.
To meet the time schedule of product delivery to customers.
Reduces the downtime of the machines.
To reduce the cost of downtime, it means when your machine’s downtime will be reduced then the idle time of the machine, workers, etc. will remain reduced and the respective cost as well. And others cost shall be reduced like scrap cost, rework cost, repair cost, maintenance labour, and overhead cost, etc.
To prolong the useful life of the machine and equipment.
To provide a condition of the machine that would permit their operation in the manner required for the process and without interruption to plans involving their use.

Maintenance:

We have already mentioned above the benefits of maintenance that why it is important in manufacturing industries, but anyway it is classified into many types based on different and different factors/ rules /operations, etc. Like [1] Mechanical maintenance, [2] Utility maintenance, [3] Electrical maintenance, [4] Machine maintenance, [5] Tool maintenance, etc. And similarly, it is also classified into different types like Preventive maintenance, Predictive maintenance, Breakdown Maintenance, Capital replacement, Planned maintenance, Schedule maintenance, and Corrective maintenance. Etc.

What is Preventive Maintenance?

Preventive maintenance is routine / time-based maintenance where actions are taken in a planned manner to prevent the breakdown of the machine. The main aim is to find out the problem and to fix it before it creates an issue. Generally, in industries, the common popular types of maintenance are used as [1] Preventive and, [2] Predictive maintenance. And also some industries followed and implemented the TPM activities.

Advantages of PM (Preventive Maintenance):

Prolongs asset lifespans.
Increased productivity and production.
Greater safety of the workforce.
Reduces the breakdown and increases the MTBF time.
Reduce the scraps, rejection, and rework of products.
Lower repair and maintenance costs, etc.

How to start or deploy Preventive Maintenance in Manufacturing Industries?

I am going to share my own experience here, whatever I have learned from a decade of time. Both preventive and predictive maintenance is a useful activity in manufacturing industries. So, if you would like to start Preventive maintenance in your organization then, just follow the below steps.

Step-1:

Go through the past data of breakdown process-wise / area-wise, then workstation-wise, and finally machine-wise. And also carefully read the machine manual, drawing, and related documents to understand the machine function, lubrication system, hydraulic system, etc.

Step-2:

Prepare the fishbone/cause & effect / Ishikawa Diagram of all failures.

Step-3:

Prepare the Standard Operating Procedure.

Step-4:

Prepare the Preventive maintenance check sheet / Checklist.

Step-5:

Prepare the activity road map including the responsibility for each and every activity, plan, and schedule.

Step-6:

Implement the road map, SOP, plan, schedule, and do checking w.r.t check sheet/checklist.

Step-7:

Analyze the data and take the action.

Step-8:

Review and update the documents like SOP, and check-sheet.

Step-9:

If applicable, do the horizontal deployment.

Example:

We have decided to start the Preventive maintenance of Process-1, Process-2, and Process-3, So accordingly both plan and schedule have been prepared.

Preventive Maintenance Plan of Process-1, having total 4 machines, M1, M2, M3 & M4.

Month	Week-1	Week-2	Week-3	Week-4
Jan.	M1	M2	M4	M3
Feb.	M3	M1	M2	M4
Mar.	M3	M4	M1	M2
Apr.	M4	M3	M2	M1
May.	M3	M2	M1	M4
Jun.	M2	M1	M4	M3
Jul.	M1	M2	M3	M4
Aug.	M4	M1	M2	M3
Sep.	M3	M4	M1	M2
Oct.	M4	M3	M2	M1
Nov.	M3	M2	M1	M4
Dec.	M2	M1	M4	M3

Annual PM Plan

After consultation with the production department and considering machine availability Sr. Maintenance Engineer has prepared the Preventive maintenance schedule and carried it out accordingly.

PM Schedule for the Month of Jan’yyyy.

M/C	Week-1	Week-2	Week-3	Week-4
M1-Plan	4.4.yy /Sunday
Actual
M2-Plan		11.4.yy/Sunday
Actual
M4-Plan			18.4.yy/Sunday
Actual
M3-Plan				24.4.yy/Saturday
Actual

Monthly PM Schedule

What is Predictive Maintenance?

Predictive maintenance is condition-based maintenance that monitors the condition & performance of equipment to reduce the probability of failure.

Advantages of Predictive Maintenance:

Improve asset reliability.
Provide better product quality.
Improve the condition of equipment, etc.

The basic requirements for good maintenance practices:

The following are the basic requirements for achieving good maintenance practices as;

Good supervision of the maintenance department.
Do the maintenance plan and schedule a consultation with the production department, electrical department, utility service department, etc., and prioritize the machine to be covered under maintenance.
Maintenance personnel should be well-trained.
SOP, standard, to be followed.
Adequate stock of spares should be kept.
A checklist, logbook, and maintenance register should be maintained.
5’S to be maintained.
CLIT to be followed.

Free Templates / Formats of QM: we have published some free templates or formats related to Quality Management with manufacturing / industrial practical examples for better understanding and learning. if you have not yet read these free template articles/posts then, you could visit our “Template/Format” section. Thanks for reading…keep visiting techiequality.com

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Types of Productivity with Example |Productivity Formula |Calculation

26/03/2024 by TECHIEQUALITY

Types of Productivity with Example |Productivity Formula |Calculation

Hi readers! Today we will discuss on types of productivity with example. Productivity is an economic measure of the effective use of resources. It means how much output is obtained w.r.t effective usages of input in a given time period.

PRODUCTIVITY: It is a ratio of output to input.

Productivity = Output / Input.

P = Value of output / Cost of Input

The units of output and input may vary from industry to industry. But some common units of outputs are KWH, Units, Tonnes, MT, litres, KG, and similarly, an input could be time, cost, etc. Inputs are resources such as labour, energy, materials etc. used to produce the output such as goods or services. And also, the output may be measured per shift, per week, per month or per hour.

Types of Productivity with Example:

Productivity is generally classified into three types as [1] Partial Productivity, [2] Multifactor Productivity, [3] Total Productivity.

Partial Productivity = Output / Single Input.

For example, a company produced 2000 pieces of finished product per day involving 2 labours per shift. Here we would like to calculate the labour productivity.

Labour productivity = 2000 / (6*8)

= 2000 / 48

= 41.66 pieces per hour.

Other common terms used to calculate the partial productivity industry are Machine productivity, capital productivity, Material Productivity, etc.

Multifactor Productivity = Output / more than one Input.

For example, a company produces 2000 pieces of finished product per day with input like labour cost $200, Machine cost $300, and material cost of $500. What is the multifactor productivity?

Multifactor Productivity = 2000 pieces / ($200+$300+$500)

= 2000 pieces/ $1000

= 2 Pieces per dollar.

Total Productivity = Output / All Input.

For calculating the total productivity you have to consider the values of output in rupees and cost of all inputs in rupees.

Note that productivity is generally calculated to know the performance, effectiveness, and etc. but the challenging thing is how to improve productivity. For doing so either you have to increase the output or decrease the input.

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5G Problem solving technique | Manufacturing Example |Free Template

26/03/2024 by TECHIEQUALITY

5G Problem solving technique | Manufacturing Example |Free Template

5G Problem solving technique is the most popular Japanese technique, this will help and guide you on how to solve problems. Many problems is being occurred day to day in manufacturing industries like machine breakdowns, customer complaints, in-process rejection problems, material problems, etc. So to tackle the everyday problem in an unsystematic way is a big challenging work. To overcome this issue, you can follow the 5S Japanese concept to resolve actual/real place problems. It’s namely called 5G because every Japanese word starts with the letter “G” i.e. [1] GEMBA, [2] GEMBUTSU, [3] GENJITSU, [4] GENRI, [5] GENSOKU; these are the 5G where you have to find out the causes. In some cases, you can propose and predict the right cause without visiting the real place and analyzing the actual facts. So this method helps you to resolve the problem.

DOWNLOAD Template- 5W1H, CAPA, 5W2H, 4M check sheet, 8D Format.

5G Problem solving Technique with Manufacturing Example:

Here I’m sharing my own experience that once upon a time I had made a great mistake during an analysis of a customer complaint, one of our customers informed us 5% of the last batch of consignment products had been rejected due to a pinhole issue. Immediately after receiving the customer complaint, we called a meeting with all my team members. And we all started discussing in the conference room to find out the cause of the problem and finally, we proposed an action plan and implemented the same but later on we faced the same problem again.

Our hypothesis / predicted root cause of the failure was invalid. From this experience, I learned that we can’t find an effective action plan by hypothesis or prediction. We must investigate the actual things and verify the principles. And finally, we applied the Japanese technique 5G for problem-solving i.e. [1] GEMBA, [2] GEMBUTSU, [3] GENJITSU, [4] GENRI, [5] GENSOKU.

Before continuing with the above example I would like to elaborate on the 5G Technique /Method.

GEMBA: Go to the Real /Actual Place.

It’s the place/location where the problem actually occurred e.g. Shop floor. First of all, we have to visit the shop floor or the actual location where we need to start the investigation.

GEMBUTSU: Examine the objects /machine/tools etc.

Your problem-solving team members should examine the machine, parts, objects, and tools that were involved in the failure. During the examination, you can find any clues of failure.

GENJITSU: Check the real Facts

Your team must collect the before and after data and test report, and the team should link the data to the actual facts that what really happened.

GENRI: Refer to the theory /verify the principle.

The team should verify the principle and condition of the machine/equipment/tools etc.

GENSOKU: Check the process parameters /SOP/Standards.

In this technique the team member should check and verify the process parameters, SOP, Work procedure, Visual instruction, and one-point lesson are followed by operators and that there is no any deviation.

How to apply 5G technique in the manufacturing industry?

We will elaborate on this section continuing with the above example that our action plan against the customer complaint (Pin-hole problem) was not valid. When we applied the 5G technique, the action plan was very effective. First of all, all the team members visited to the shop floor to know the exact problem when we examined the problem we came to know that the actual problem was a blow-hole but not a pin-hole. This was visualized when we went through the G-2 (Gembutsu).

Next, we continued the rest of three-G, some clues we found at the stage of Genjutsu from the Core curing time and some from Gensoku. That curing procedure was not being maintained as per the standard operating procedure. And finally, we concluded after completing the 5G technique on a fact basis that the core curing process was not maintained as per SOP. This is my own experience that how I could able to find out the problem causes using the 5G technique. Given below are the 5-steps, details meanings, concepts, and illustrations of 5G.

Step-by-Step Guide to 5G Problem Solving Technique Application

Step-1	GEMBA	Go to the real place	Create a team and visit to the shop floor or a place where the problem occurred
Step-2	GEMBUTSU	Examine the objects	Examine the machine /tools /equipment/non-conforming pats to know the clues
Step-3	GENJITSU	Check the real facts	Collect the data and analyze it. And also do the countermeasure.
Step-4	GENRI	Verify the principle	Verify the current practices and condition of m/c, equipment, tools, etc.
Step-5	GENSOKU	Check the standards	To check the process characteristics, SOP, and work procedure, whether it is being followed or not.

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AIAG VDA FMEA Key Changes | Overview | 7 Step FMEA |PFMEA |1st Edition 2019 | Training

26/03/2024 by TECHIEQUALITY

AIAG VDA FMEA Key Changes | Overview | 7 Step FMEA |PFMEA |1^st Edition 2019 | Training

The AIAG VDA FMEA 1^st edition handbook has been released first time jointly by AIAG (Automotive Industry Action Group) & VDA (Verband der Automobilindustrie) in 2019. Basically, FMEA is a core tool that is used to identify the potential failure modes of process and product & their cause and effects. Mainly FMEA is three types i.e. [1] PFMEA (Process failure mode and effect analysis), [2] DFMEA (Design failure mode and effect analysis), [3] MSR-FMEA. In this post, we will cover the PFMEA with a manufacturing example.

DOWNLOAD-PDF files of AIAG-VDA FMEA key changes.

If your organization is manufacturing Automotive /Automobile parts/items/products or IATF 16949 certified companies then, you are compulsory to identify the process/ product /design related failures /risks in the FMEA worksheet. It means you have to prepare and implement the FMEA in your organization as a live document. If a customer mentions in their CSR (Customer Specific Requirement) for FMEA requirement then, it’s mandatory for their supplier to fulfil the FMEA requirement, but it does not matter whether your organization is IATF-16949 certified or not. So it’s more important to understand the complete requirements of FMEA before its application in industries. In standard IATF-16949, the application of FMEA is clearly mentioned in several clauses. Now we are going to explain each and every clause of IATF-16949 those are relevant to the FMEA application.

What are the requirements of IATF 16949 for FMEA application?

There are almost 12 sub-clauses in the IATF-16949 standard, where the application and implementation of FMEA are widely explained in the IATF standard. These clauses’s requirements as explained below;

IATF-16949 Clauses /Sub-clauses No: 4.4.1.2: Special approval of PFMEA and DFMEA is required.

8.3.2.1 (IATF Sub-clause): During product development, the organization shall develop the DFMEA and require reviewing the product design risk to reduce the potential risks.

8.3.3.3 (IATF Sub-clause): Special characteristics like fit & function, Critical characteristics, significant characteristics, safety characteristics, etc. are need to be included in the FMEA worksheet.

8.3.5.1 (IATF Sub-clause): This sub-clause talks about the design risk analysis. DFMEA is the mandatory requirement for design and development output.

8.3.5.2 (IATF Sub-clause): Manufacturing process-related risks need to be addressed in PFMEA.

8.5.6.1.1 (IATF Sub-clause): Process-related risks need to be addressed in PFMEA due to temporary changes in process controls. If your organization has temporarily changed the existing process controls and using the alternative new control method then, the organization shall include the risks of new process control methods in the PFMEA worksheet.

8.7.1.4 (IATF Sub-clause): The organization shall identify the risks related to the product rework process in FMEA.

8.7.1.5 (IATF Sub-clause): The organization shall identify the risks related to the product repair process in FMEA.

9.1.1.1 (IATF Sub-clause): This clause is about the Implementation of PFMEA.

9.3.2.1 (IATF Sub-clause): Field failure /warranty failure-related risk needs to be addressed in FMEA.

10.2.3 (IATF Sub-clause): As and when problems arise in the process, accordingly review and updation of PFMEA are required.

10.2.4 (IATF Sub-clause): Error proofing details methodology needs to be addressed in PFMEA.

Key Changes of AIAG-VDA PFMEA, 1^st edition 2019:

*4^th edition FMEA (Old version manual)*	*AIAG-VDA FMEA (New version handbook)*
RPN (Risk priority number) = S x O x D	Action Priority (AP) Table.
Old Severity, Occurrence & Detection Ratings	Revised Severity, Occurrence & Detection Ratings
Old worksheet (Format/ Template)	Revised worksheet (Format/ Template)
PFD was not an integral part	The Process flow diagram is an integral part of the new manual
Recommended action	Prevention & detection action
Classification	Special Characteristics
	4M-Men, Machine, Material, and Method approach

The complete PFMEA worksheet has made considering 7 Steps FMEA approach, i.e. [1] Planning & Preparation, [2] Structure Analysis, [3] Function Analysis, [4] Failure Analysis, [5] Risk Analysis, [6] Optimization and [7] Risk Communication.

7 Steps PFMEA Approach:

Planning & Preparation:

This is the first step of the FMEA 7-step approach, A Cross-functional team needs to be formed and their roles and responsibilities need to be assigned. In the worksheet, you have to mention those things like Company name, location, PFMEA ID, Confidential Level, etc.

Structure Analysis:

In SA, You have to identify the Process steps i.e. PFD, here you have to identify mainly three things, Process Item, step, and work element (4M).

Function Analysis:

You have to describe the function process item in the next plant process, end-user, and customer, and Simultaneously Process and product characteristics need to be identified.

Failure Analysis:

Here you have to identify the failure effect, mode, and cause.

Risk Analysis:

Current prevention & detection control, AP, SC, etc. need to be addressed.

Optimization:

According to the Level of AP (Action Priority), if required to take the action then, you have to complete the optimization step and again you have to level the PFMEA-AP.

In the previous version, there is a calculation of RPN, but in the new FMEA there is no calculation, just you have to identify the level from the Action Priority Table. Priority High AP level means you must be required to identify appropriate action, Medium priority AP level means you should identify appropriate actions and finally Low priority level (L) means you could identify actions to improve prevention or detection controls.

Result Documentation / Risk Communication:

Now, you have to keep the documents like result communication, CFT meeting report, etc.

7 Steps to Implement the New AIAG-VDA PFMEA in Industry?

In each and every post our authors are trying to share their experience with industrial examples so that the common man can easily understand, learn, and implement it in their workplace. Also, we are always trying to enhance the skill base knowledge of our readers. Anyway, go through the below steps to implement the new PFMEA manual.

Step-1:

To form a CFT team, for example, members should be from different functions like Production, Maintenance, Process quality, product quality, R&D function, etc.

Step-2:

Use the process flow diagram to identify each step of all processes.

Step-3:

Visit the workplace and understand the operational function of each and every step of the process and 4M factors.

Step-4:

Brainstorm the potential failure mode and its effects. accumulate the previous failures from any resources like from shop floor supervisors, operators, from old data, failure due to 4M factors (Man, Machine, Material, Method, etc), and list up the potential effect of failures as well.

Step-5:

To rank the Severity, occurrence, and detection and accordingly choose the level of Action Priority from the AP table.

Step-6:

To address the Current control mechanism in the worksheet.

Step-7:

Take action as per AP level and after implementation of the Action Plan, you have to re-level the PFMEA action priority.

FAQ:

Q1: Shall I need to convert our Approved old PFMEA worksheet to the new one?

A1: Actually it depends upon your customer’s needs and what they want, they need to keep the old approved copy or need the re-approved copy as per the new manual. If your customer asks for a new worksheet as per the 1^st edition of AIAG-VDA PFMEA then only you need to change the old one.