Page 116 - TPM A Route to World-Class Performance

The TPM improvmf plan 97

Step 7Asset care
Once refurbishment of an item of equipment has been carried out, a future
asset care programme must be defined to ensure that the machine condition
is maintained. It is therefore necessary to establish:

cleaning and inspection routines
checking; and condition monitoring methods and routines
planned preventive maintenance and service schedules

For each of these we must develop:
0 improvements to make each task easier
visual techniques to make each task obvious
training to achieve consistency between shifts
It is important to distinguish between natural and accelerated deterioration.
In the course of normal usage, natural deterioration will take place even
though the machine is used properly. Acceluafed deterioration arises from
outside influences. These are equipmmnt-based, i.e. failure to tackle the mot
causes of dust, dirt and contamination; and operutor-based, i.e. Mure to maintain
basic conditions such as cleaning, lubricating and bolting, and also human
operational errors.
Figures 5.20 and 5.21 show how the care of assets may be broken down
into elements which reflect the first three steps of the conhtion cycle: a-iticality,
condition and refurbishment. Figure 5.22 illustrates the relationship between
operational and technical aspects of asset care. Some key points for
consideration in asset care are shown in Figure 5.23.
The question of training is developed fully in Chapter 7, but some key
approaches are dustrated in Table 5.1. A training schedule form is shown in
Figure 5.24. This schedule is completed through a series of single-point, on-
the-job lessons.
A practical example of daily cleaning and inspection is gven in Figure
5.25. This shows the checks to be made in a MIG welding cell for each shift
during the working week, and records all the daily checks made by the
operators. A material usage dwt first developed to highhght loss measurement

Mechanical Hydraulic Electrical coohg

- Fdter~ - Motors - Cmlmt
Bearings -oil - Fuses - pipes
Fasteners
Drivers
Figure 5.20 Stages in asset care