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Autonomous Maintenance Presentation PDF

The document outlines abnormalities or issues to look for during autonomous maintenance for Total Productive Maintenance (TPM). It lists types of abnormalities such as dust, dirt, leaks, rust, loose parts, and damage. Specific areas to inspect are also identified like bolts and nuts, lubrication systems, pneumatics, hydraulics, and safety features. Potential abnormalities are described for each area.

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Fachry
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438 views70 pages

Autonomous Maintenance Presentation PDF

The document outlines abnormalities or issues to look for during autonomous maintenance for Total Productive Maintenance (TPM). It lists types of abnormalities such as dust, dirt, leaks, rust, loose parts, and damage. Specific areas to inspect are also identified like bolts and nuts, lubrication systems, pneumatics, hydraulics, and safety features. Potential abnormalities are described for each area.

Uploaded by

Fachry
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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TPM – JISHU HOZEN : STEP 1

AUTONOMOUS MAINTENANCE : STEP1


FUGAIS ( ABNORMALITIES ) – WHAT : WHERE

TPM – JISHU HOZEN : STEP 1


AUTONOMOUS MAINTENANCE : STEP1
WHAT ARE
ABNORMALITIES?
▪ DUST
▪ DIRT
▪ LEAK
▪ RUST
▪ LOOSE
▪ DAMAGE
▪ DEFORMED
▪ NON STANDARD
▪ VIBRATION
▪ NOISE
▪ MIS ALIGNMENT
▪ SHAKING
▪ WORN OUT
▪ MISSING PARTS
WHERE TO FIND
ABNORMALITIES?
▪ BOLTS AND NUTS
▪ LUBRICATION
▪ TRANSMISSION
▪ HYDRAULICS
▪ PNEUMATICS – GAS SYSTEM
▪ ELECTRICAL
▪ SAFETY
BOLTS & NUTS
BOLTS & NUTS- Fugais to look out for
( Typical but not exhaustive ..)
❑ More(Max ? )No. of Treads

❑ Nut Missing in the bolt

❑ Non Standard Bolts

❑ Screw Missing

❑ Bolt Bend

❑ Non Uniform washer

❑ Rust in the Bolt ……..


BOLTS & NUTS- Fugais to look out for
❑ More(Max ? )No. of Treads
BOLTS & NUTS- Fugais to look out for
❑Nut Missing in the bolt
BOLTS & NUTS- Fugais to look out for
❑Non Standard Bolts
BOLTS & NUTS- Fugais to look out for
❑Screw Missing
BOLTS & NUTS- Fugais to look out for
❑Bolt Bend
BOLTS & NUTS- Fugais to look out for
❑Non Uniform Washer
BOLTS & NUTS- Fugais to look out for
❑ Rust (Corrosion ) in the Bolt

Rust in the Bolt


▪ LUBRICATION SYSTEM
▪ LUBRICATION SYSTEM : Fugais to
look out for ( Typical but not exhaustive)
❑ Lubrication System Not Working

❑ No Grease in Reservoir

❑ No Visibility

❑ No Oil in the Gear Box

❑ Lubrication Level Low /High

❑ Grease / oil - Leak

❑ Without Grease Nipple & Cap

❑ Reservoir Tank Open

❑ Excess Greasing

❑ Oil / Grease Dust Contamination


❑Lubrication System NOT Working
❑No Grease in Reservoir
❑No Visibility
❑No Oil in the Gear Box
❑Lubrication Level Low /High
❑Grease / Oil - Leak
❑Without Grease Nipple & Cap
❑Reservoir Tank Open
ELECTRICITY
▪ ELECTRICAL SYSTEM : Fugais to
look out for ( Typical but not exhaustive)
❑ Cooling Fan for Motor

❑ Unwanted Things Inside Panel

❑ Wires on Floor

❑ Panel in Open Condition

❑ Unwanted holes on the Panel

❑ No proper Earthing

❑ Loose & Excess Wires

❑ Improper Laid Wiring

❑ Abnormal sound from Motor

❑ No Proper Gland

❑ Limit Switch not fixed properly


❑ No Cooling Fan for Motor
❑ Unwanted Things Inside Panel
❑Panel in Open Condition
❑Wires on Floor
❑Unwanted holes on the Panel
❑No Proper Earthing
❑Loose & Excess Wires
❑Loose & Excess Wires
❑Abnormal Sound from Motor
❑No Proper Gland
❑ Limit Switch not fixed properly
PNEUMATICS
Pneumatic:
❑ FRL – No Visibility in Bowl
❑ FRL – Not Fitted Properly
❑ Pressure Gauge - Damage
❑ Pressure Gauge – No Needle
❑ Pressure Gauge – without Glass
❑ FRL – Not Routed Properly
❑ Dirt in the Filter Bowl
❑ Water Contamination in Filter
❑ No oil in Lubricator
❑ Oil in Lubricator contaminated
❑ Air Leak /Gas Leek
❑ Filter Placed Horizontal
❑ No Visibility in Bowl
❑ FRL – Not Fitted Properly
❑ Pressure Gauge - Damage
❑ Pressure Gauge – No Needle
❑ Pressure Gauge – without Glass
❑ FRL – Not Routed Properly
❑ Dirt in the Filter Bowl
❑ Water Contamination in Filter
❑ No oil in Lubricator
❑ Oil in Lubricator contaminated
❑ Air Leak /Gas Leek
❑ Filter Placed Horizontal
HYDRAULIC
❑ Hydraulics:

❑ Water/Oil Leak – Pipe Line Damage


❑ Steam Leak in Hose
❑ Steam Leak in Flange
❑ Abnormal sound in Hydraulic Line
❑ Pressure Gauge – Damage , No
Needle ,No Glass
❑ Lines Not Routed Properly
❑ Water/Oil Leak – Pipe Line Damage
❑ Steam Leak in Hose
❑ Steam Leak in Flange
❑ Abnormal Sound in Hydraulic Line
❑ Pressure Gauge – Damage , No
Needle ,No Glass
❑ Lines Not Routed Properly
TRANSMISSION
❑ Drive Unit ( TRANSMISSION )
❑ Mis Alignment
❑ Without Safety Guard
❑ Shaft damage / Worn Out
❑ Belt - Missing / Loose / Tight
❑ Chain - Loose / Tight
❑ Crack in Pulley
❑ Pulley / Sprocket – Key,Keyway Damage
❑ Pulley / Sprocket – Damage
❑ Mis Alignment
❑ Without Safety Guard
❑ Belt - Missing / Loose / Tight
❑ Chain - Loose / Tight
❑ Crack in Pulley
❑ Pulley / Sprocket – Key,Keyway Damage
❑ Pulley / Sprocket – Key,Keyway Damage
❑ Pulley / Sprocket – Damage
Safety :
❑ Safety Bar / Rope not working
❑ Without Splash Guard
❑ No Emergency Switch
❑ No proper Gland in the Wire
❑ Improper Laying of Cables
❑ Working While Press Closing
❑ Standing in front of press while
opening
❑ Standing in the Mould

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