Five Countermeasures to achieve Zero breakdowns

1. Establish basic 2. Adhere to usage 3. Restore defective 4. Correct design

equipment conditions
of,
· Clean equipment: RCA of
contamination and apply
corrective action.
· Tighten: Prevent fasteners
from loosening.
· Lubricate correctly:
Identify lubrication
requirements and
positions.
· Improve work methods
and equipment.
· Resolve difficult work
areas.
· Set and follow cleaning
and lubricating standards.
condition of equipment,
· Identify design condition
of mass produced parts
and vendors’ instruction.
· Standardise design
conditions.
· Set and improve usage
conditions in terms of
parts and subassemblies,
and equipment.
· Properly install
equipment.
· Prepare accurate
operating procedures and
supply to production
department.
· Adhere to given operating
conditions and
procedures.
parts,
· Determine categories for
overall inspection.
· Execute inspection
education and practice for
operators.
· Conduct overall
inspection.
· Set and follow routine
inspection standards
· Identify adequate MTBF
based on results of routine
inspection.
· Extend intervals for parts
replacement and
overhaul.
· Conduct condition
monitoring and machine
diagnosis
weaknesses, 5. Enhance operation and maintenance skills
· Improve equipment to
extend lifetime: structure
and mechanism, shape
and material, dimensional
Operation Maintenance
accuracy, assembling
· Analyse each occurrence · Analyse ppm activities
accuracy and strength
of misoperation and carry and improve where
resistance to corrosion
out counter measures. required.
and erosion, etc.
· Poke Yoka if possible. · Improve strip down and
· Analyse and remedy
assembly procedures.
kinetic condition of
· Apply visual controls.
equipment.
· Establish spare parts
· Standardise operating and control system.
adjusting procedures.
· Poka Yoke where
possible.
· Apply visual controls
· Standardise servicing
procedures.

Production Department: Maintenance Department:

· Operation and manual manipulation · Check and inspect

· Inspecting and lubricating · Repair and overhaul
· Setup and adjustment · Condition monitoring and machine diagnosis
· Detection of abnormal signs · Establish planned maintenance system PPM