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Systematic Maintenance-2017 PDF
Systematic Maintenance-2017 PDF
ARMANDO R. DIAZ
Master of Science in Business Administration (MBA)
ASEAN CHARTER PROFESSIONAL ENGINEER
Professional Electrical Engineer ( PEE )
Registered Master Plumber
Certified Plant Mechanical( CPM )
Accredited Pollution Control Officer
Licensed Professional Engineer with more than 40 years experience in the field of
building and facility design, consultancy, construction, operations and maintenance
involving various mechanical electrical plumbing and fire protection system
MEPF Design and Project Management : PEPSI Cola , Sto. Tomas Plant
MEPF Design and Quality Control : ARUZE Mfg. Plant, LISP 3
Design and Consultancy : DASHEN Beer Brewery ( Ethiopia)
Design and Consultancy : SPT Clark
Design and Consultancy : Laguna Water District
MEPF Design and Project Management : PRICON Microelectronics
MEPF Design and Consultancy : AREZA Commercial Complex
Design and Consultancy : PTRI-DOST Bldg. Rehabilition
Design and Consultancy : ERDB-DENR Bldg. Rehabilitation
Design and Consultancy : HENKEL Expansion Plant
Design and Project Management : Rong Bo Yu Injection Plant
2/18/2017
Consultancy Works :
SOUTHEAST ASIA FOOD INC. ( Datu Puti )
C.T. Chun Inc.
Coral Bay Nickel Project ( Palawan )
Ligo Sardines ( Zamboanga )
Multiflex RNC Phil. (URATEX )
St. Luke Hospital ( Global City ) : Consulting Services
Electrical Project Evaluation on the integrity of Grounding System
Global Power ( Toledo City ) : Consulting Services
Evaluation of present capacity to determine the size of their
expansion project
Present Job :
MEPF ENGINEERS CO. : Principal Engineer and Partner
KANG HARO ENGINEERING : CEO and Partner
2/18/2017
PLEASE VISIT GOOGLE : armando r diaz iiee
SYSTEMATIC MAINTENANCE
4-FOUR SYSTEM
Topic Highlight
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OBJECTIVES
Operational objectives:
1. To maintain equipment
(a) in acceptable condition
(b) in top operating conditions
2. To ensure maximum availability for plant and
equipment at reasonable cost
3. To provide service that will avert breakdowns at all
times at any cost
4. To extend plant life to the last limit?
5. To maintain plant and equipment with maximum
economy and to replace at predetermined periods
6. To ensure high - quality performance.
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BENEFITS
Expressed in
The Factors Important for
terms of
Co-ordination between
Improved
1. production and Internal planning
understanding
maintenance
Unproductive Manpower
2. Manpower planning
time utilization
3. Planning of deliveries Cost of delays Plant utilization
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BENEFITS
- What do we expect to gain from good
maintenance?
C. Technical advantages
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BENEFITS
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BENEFITS
- What do we expect to gain from good
maintenance?
E. Customer relations
Expressed in Important
The Factors
terms of for
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POLICIES
- By what means shall we proceed, within limits
shall we try to work towards our objectives?
Production
operations 2
Management
Policies 3
Maintenance
Policies 1 Personnel
practices 4
Union
Relations 5
Financial
Objective 6
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MAINTENANCE
ORGANIZATION
MAINTENANCE MANAGER
MECHANICAL
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What does MAINTENANCE really
do?
• What constitutes maintenance work?
• The equipment is brand new and highly automatic, all it needs is a few drops of oil
in the right place.
• We have had no trouble for many years just as we are, these are study machines so
why worry?
• Our operators have instructions to take good care of their machines and it works!
• We have tried to get experienced men for years, but in this area, they are simply
not available.
• We rely on outside contractors. They are right next door, you know!
• Our foremen knows all the machines like the back of his hand, we do not need a
system to tell us what’s wrong
• We have bunch of good labs,they work hard and would resent being tied down by
procedures
Recording of Relevant
Data
1. Management techniques
2. Clerical procedures Analysis of need
Breakdown Elimination
3. Technological Practices
Implementation
4. Personnel management
Planning and 1. Design Improvements
5. Financial/operational controls
Scheduling
2. Change of schedules
Controls 3. Service specifications
Reporting
Breakdown Maintenance
“Don’t do a thing until you see smoke
rising”
Breakdown Maintenance
Normally this approach is referred to as a “repair”
maintenance but it is not in the true sense a system at all
because there is no service is carried out unless a failure has
occurred. In so doing, what we really needs on this approach
is obtaining full information of breakdowns. Having these
formations, discussions has to be done for us to arrive a
solution to avert recurrence of the same nature by:
•Tasting
Routine Maintenance
Second Level Maintenance, some activities are:
ARCING / SPARKING
VIBRATION / SOUND
CARBON BRUSH
TEMPERATURE
DESCRIPTION REMARKS
1 EXTRUSION
=211+R12-M021 Rotary Valve Big Bag Station Motor
=213+R12-M011 Vaccum Feeder MB1 Motor
=213+R12-M013 Vaccum Feeder Pearlized Motor
=216+S11-M011 Granulate Con. Fan Ext. Feeding
=216+S11-M021 Hopper Mixer Motor
=311+H12-M131 Main Extrusion Gear Oil Pump 1
=214+S11-M023 Dos. Unit Coex2 MB2 Suction Motor
15
Shift -In- Charge: _________ _________ _________ Section Leader : _____________ _______________
ELECTRICAL DAILY CHECKLIST
DATE __________________ TIME __________________
ARCING / SPARKING
CARBON BRUSH
TEMPERATURE
DESCRIPTION REMARKS
2 REGRANULATION
=392+A 92-M 031 Was te Grinder Motor
This approach is very costly and need some statistical data and
analysis. To established this system immediately, we need
information on the manufacturer for the life of their machine.
Preventive Maintenance
To achieve the prevention of breakdowns, planned service is carried
out with the explicit additional objective of detecting weak points
and ensuring perfect functioning by replacing parts which could still
be used were it need for the assurance that we required.
Thus after the service a machine is “as good as new” and high degree
of reliability.
Preventive Maintenance
Naturally, the cost of running this system
is high and it is therefore be applied
only in the cases of
absolute necessity.
STEPS IN PREPARATION OF
MAINTENANCE PROGRAM
1. Identify and list all equipment installed to be maintained
2. Provide checklist for the equipment and machines (First Level Maintenance)
3. Provide service schedule as per manufacturer’s recommendation or industry
standard (Second Level Maintenance)
4. Prepare Plan Maintenance Schedule for one year
5. Prepare Preventive Maintenance just after you have statistical data or
knowledge
6. Attach service control tag to equipment
7. Implement and monitor all maintenance schedules
8. Record all activities to Equipment History Card (EHC)
PAPERWORK
b. Planned Maintenance
c. Preventive Maintenance
Planned Maintenance
Preventive Maintenance
– Staffing
– Responsibility to stock
– Paperwork sequence
– Inventory taking
Problems relating to the operation of
maintenance stores
C.Physical Facilities
– Size of stores,layout,gates,mezzanines,etc.
– Grouping of materials
– Standardization
– Reordering quantity
– Obsolescence
– Costing of items
– Contract suppliers
– Risk of obsolescence
STOCK CONTROL
An Approach to Replacement Procedures
– Morale boosters
– Competence of supervisors
LEGEND :
3 Normal s For Repair / with abnormalities
m Not Applicable k Need Urgent repair
AIR COMPRESSOR
AIR COMPRESSOR
1 2 3
PACKAGE DISCHARGE PRESSURE (RATED)
FIRST STAGE DISCHARGE TEMP (250 C)
SECOND SHIFT
EVAPORATOR PRESSURE 2
CONDENSER PRESSURE 3
ACTIVE CHILLED WATER SET POINT(SP)
EVAPORATOR ENTERING WATER TEMP
EVAPORATOR LEAVING WATER TEMP
OUTDOOR AIR TEMP
Blockage Indicators
Fluid Tem perature
Water Coolers
External leaks
REMARKS
Air Coolers
Fluid Level
Dam age
Noise
EQUIPMENT
Dirt
Main Extrusion Gear Oil Pump 1
Main Extrusion Gear Oil Pump 2
MONDAY
Co-Extruder 1 Gear Oil Pump
Co-Extruder 2 Gear Oil Pump
Waste Grinder Hydraulic Pump
Compactor Hydraulic Pump Motor
TUESDAY
TDO Chain Lubrication Pump Inlet
TDO Chain Lubrication Pump Outlet
TDO Bolt Lubrication Pump
TDO Hydraulic Pump Chain Tension
WEDNESDAY
TDO Edge Guide PneumoHydralic Pump OS
TDO Edge Guide PneumoHydralic Pump DS
Edge Trim Grinder Hydraulic Pump Motor
Winder Hydraulic Pump Motor
THURSDAY
Main Slitter Hydraulic Pump
Secondary Slitter 1 Hydraulic Pack
Secondary Slitter 2 Hydraulic Pack
Secondary Slitter 1 Edge Guide Hydraulic
FRIDAY
Secondary Slitter 2 Edge Guide Hydraulic
Cigarette Slitter Hydraulic Pump
Re marks : Re marks :
Le ge nd:
O - Normal
X - Ne e d Re pair
RC - Re pair Comple te d
RECOMMENDATION
Date:
Legend:
Checked By:
AVFM
RECOM M ENDATION
No. ____________
• PREVENTIVE (TIME-BASED)
• PREDICTIVE (CONDITION-BASED)
• PROACTIVE (RELIABILITY-
BASED)
THANK YOU
E-mail Address :
ard4len@yahoo.com
Tel.No.(049) 576 5060
Smart: 0918 909 4164
Sun : 0932 821 1050
Globe: 0917 575 7630
SERVICES
• BUILDING REPAIR AND MAINTENANCE
• CIVIL & STRUCTURAL DESIGN & BUILD
• ELECTRICAL INSPECTION AND SAFETY AUDIT
• POWER QUALITY ANALYSIS ( PQA )
• THERMAL SCANNING
• TRANSFORMER SERVICING
• MEPF TESTING & COMMISSIONING
• ELECTRICAL AND MECHANICAL AS-BUILT DRAWING