UNIVERSITI TEKNIKAL MALAYSIA MELAKA
Autonomous Maintenance Programme on
Grinding Machine for Job Base
Report submitted in accordance with the requirements of the Universiti Teknikal Malaysia Melaka for the Bachelor’s Degree in Manufacturing Engineering
(Manufacturing Management)
By
Ilyana Binti Abdullah
Faculty of Manufacturing Engineering
oval
UTeM Library (Pind.1/2005)
UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)
BORANG PENGESAHAN STATUS TESIS*
JUDUL: AUTONOMOUS MAINTENANCE PROGRAMME ON GRINDING MACHINE FOR
JOB BASE.
SESI PENGAJIAN: 2007/2008
Saya ILYANA BINTI ABDULLAH
mengaku membenarkan tesis (PSM/Sarjana/Doktor Falsafah) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:
1. Tesis adalah hak milik Universiti Teknikal Malaysia Melaka.
2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan untuk tujuan pengajian sahaja.
3. Perpustakaan dibenarkan membuat salinan tesis ini sebagai bahan pertukaran antara institusi pengajian tinggi. atau kepentingan Malaysia yang termaktub di dalam AKTA RAHSIA RASMI 1972)
(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/badan di mana penyelidikan dijalankan)
(TANDATANGAN PENULIS)
* Tesis dimaksudkan sebagai tesis bagi Ijazah Doktor Falsafah dan Sarjana secara penyelidikan, atau disertasi bagi pengajian secara kerja kursus dan penyelidikan, atau Laporan Projek Sarjana Muda (PSM). ** Jika tesis ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh tesis ini perlu dikelaskan sebagai SULIT atau TERHAD.
iii
DECLARATION
I hereby, declared this Bachelor’s Project entitled “Autonomous Maintenance
Programme on Grinding Machine for Job Base” is the result of my own research except as cited in references.
Signature :
Author’s Name : Ilyana Binti Abdullah
iv
APPROVAL
This Bachelor’s Project submitted to the senate of UTeM and has been accepted as fulfilment of the requirement for the Degree of Bachelor of Manufacturing Engineering (Manufacturing Management) with Honours. The member of the supervisory committee
is as follow:
………
Mr. Wan Hasrulnizzam Wan Mahmood Project Supervisor
v
ABSTRACT
The heart of Total Productive Maintenance (TPM) is Autonomous Maintenance (AM), whose mainly principle lies in the first three steps of AM; Initial Cleaning, countermeasure at the source of the problems and cleaning and lubricating standard. This project spanned over a time period of seven weeks (16 January 2008 – 5 March 2008) on
vi
ABSTRAK
vii
DEDICATIONS
For my beloved parents:
Abdullah Bin Omar Che Mah Binti Che Noh
For my cherish brothers and sisters
viii
ACKNOWLEDGEMENTS
Bismillahirrahmanirrahim…
This thesis would not have been possible without the contribution of several important people.There is a number of people I want to thank for their help and support in writing this thesis. Some of them are legends, like Taichi Ohno, Shigeo Shingo, W. Edwards Deming, and Siiechi Nakajima. Others have become anonymous in the mist of time.
A special word of thanks is due to the people closer to me. Friends and colleagues who gave me opportunity to develop my writing, all UTeM lecturers and staffs especially to my PSM Supervisor, Mr. Wan Hasrulnizzam Bin Wan Mahmood who have taught and relayed the techniques and knowledge. I believe his guidance and advice has made this a much better thesis.
Last, but not least, my gratitude to my family who have shown an extraordinary amount of patience and tolerate in supporting me writing this thesis. And with the blessing of Allah I could finish this thesis. My thanks and gratitude to you all.
ix
List of Abbreviations, Symbols, Specialized Nomenclature………...…...xviii
1. INTRODUCTION……….1
2.1 Introduction to Maintenance………....5
2.2 Evolution of Maintenance Concept………...7
2.3 Importance of Maintenance………...…….….9
2.4 Types of Maintenance ………...10
2.4.1 Breakdown Maintenance……….11
2.4.2 Preventive Maintenance (PM)………12
2.4.3 Predictive Maintenance………...13
2.4.4 Time Based Maintenance (TBM) Also Called Periodic maintenance……13
2.4.5 Corrective Maintenance………..14
2.4.6 Failure - Finding Maintenance………15
x
2.4.8 Reliability-Centered Maintenance (RCM)………. 15
2.5 Total Productive Maintenance (TPM)……… …………..16
2.5.1 TPM Definitions……….……….16
2.5.2 Pillars of TPM……….……… 20
2.5.2.1 Pillar 1- 5S………..………...…….………...21
2.5.2.2 Pillar 2 - AM or Jishu Hozen (JH)………22
2.5.2.3 Pillar 3 - Kobetsu Kaizen………...23
2.5.2.4 Pillar 4 - Planned Maintenance……….……….24
2.5.2.5 Pillar 5 - Quality Maintenance……….…………..25
2.5.2.6 Pillar 6 - Training and Education……….………..25
2.5.2.7 Pillar 7 - Office TPM……… ………27
2.5.2.8 Pillar 8 - Safety, Health and Environment……….27
2.5.3 Overall Equipment Effectiveness (OEE)……….28
2.6 Autonomous Maintenance……….31
2.6.1 Introduction to Autonomous Maintenance………..31
2.6.2 Steps to Autonomous Maintenance……….32
2.6.2.1 Step Zero………...………32
2.6.2.2 Step 1- Initial Cleanup……….…..33
2.6.3.3 Step 2- Counter Measures……….34
2.6.3.4 Step 3- Cleaning and Lubrication Standard………...36
2.6.3.5 Step 4- General Inspection………36
2.6.3.6 Step 5- Autonomous Inspection………37
2.6.3.7 Step 6- Organization and Tidiness………38
2.6.3.8 Step 7- Full Autonomous Maintenance……….39
2.6.3 Fuguai……….39
3. GRINDING MACHINE (MODEL: BO 300 A) ………...41
3.1 Grinding Machine………..41
3.1.1 Types of Grinding Machine……….41
3.1.2 Grinding Wheels………..43
3.1.3 Grinding Fluids………45
3.2 Grinding Machine (Model: BO 300 A)……….46
3.2.1 Technical Data………47
xi
5. ANALYSIS AND DISCUSSION S………...64
xii
6.2 Recommendations………...……..……….95
6.2.1 Current Study………...95
6.2.2 Future Studies………..97
7. REFERENCES……….98
APPENDICES
A Main Spreadsheet for Fuguai Analysis
xiii
2.6 Seven Steps for Developing Autonomous Maintenance 22
2.7 Improvement Categories 23
2.8 Six Steps in Planned Maintenance 24
2.9 Phase of Skills 26
2.10 Overall Equipment Effectiveness Model 30
xiv
xv
NO TITLE PAGE
5.9 Area1:- Front 67
5.11 Area3:- Left Side 68
5.12 Area1 Tagged with F-Tags 69
5.13 Area2 and Area3 are Tagged with F-Tags 70
5.14 The Trend Chart of Fuguai vs Week 73
5.15 The Pareto Chart for Fuguai. 74
5.16 Fuguai and Weekly Chart 76
5.17 Percentage of Fuguai for Each Area 79
5.18 Fuguai Frequency versus Area 80
5.19 Trend of Fuguai for Each Area 81
5.20 Trend of Types of Fuguai Frequency versus Week 83 5.21 Types of Fuguai versus Week for Area 1: Front 84 5.22 Types of Fuguai versus Week for Area 2: Right Side 84 5.23 Types of Fuguai versus Week for Area 3: Left Side 85
5.24 Area 1: Front before Initial Cleaning 86
5.25 Area 1: Front after Initial Cleaning 86
5.26 Area 2: Right Side before Initial Cleaning 86
5.27 Area 3: Left Side before Initial Cleaning 86
5.28 Area 2: Right Side after Initial Cleaning 86
xvi
4.2 The Differences between Primary and Secondary Data 58
4.3 The F-tags and the description 63
5.1 The standard criteria for each fuguai 65
5.2 Inspection checklist for Grinding Machine (Model: BO 300A) 71 5.3 Data Collection Of Fuguai Frequency for Seven Week 72
5.4 Data of Fuguai Frequency 78
5.5 Frequency of Types of Fuguai in the Three Areas 82
5.6 Frequency of Types of Fuguai 82
5.7 Machine Condition Before and After Initial Cleaning 86
xvii
FKP - Fakulti Kejuruteraan Pembuatan F-tag - Fuguai Tag
NPC - National Productivity Corporation OEE - Overall Equipment Effectiveness
xviii
Rev - Revolution
SOP - Standard Operating Procedure TBM - Time Based Maintenance TPM - Total Productive Maintenance TQM - Total Quality Management
UWM - University of Wisconsin - Milwaukee
WC - Work Centre
1
CHAPTER 1
INTRODUCTION
1.1 Background
Most industrial production systems are subject to deterioration with usage and age. Such system deterioration may lead to higher production costs and lower product quality and the increased possibility of breakdown (Wang and Hwang, 2004). Therefore, a well-planned maintenance management program is important to reduce costly breakdowns (Dohi et al., 2001). In some cases, system failure leads to uncountable costs, for example, the failure of an airplane engine during flight may bring property damage and loss of life. Therefore, extensive maintenance is necessary to improve the system availability (Murthy and Hwang, 1996).
Total Productive Maintenance (TPM) is a proactive and cost-effective approach to equipment maintenance which is widely adopted in Japanese industries with successful results (Nakajima, 1988). The successful implementation of TPM depends on a number of factors, such as a culture of mutual trust, operators agreeable to providing basic care to their machines, and maintenance personnel trained in management and people skills (Albert and Chan, 2000).
2
management information systems, tracking and introduction of new maintenance technologies, training and development of production and maintenance workers.
Total employee involvements, autonomous maintenance, small group activities to improve equipment reliability, maintainability and productivity, and continuous improvement, or kaizen are the principles embraced by TPM (Tsang and Chan, 2000). One of the main arms of TPM is Autonomous Maintenance (AM), called as Jitshu Hozen (JH) in Japanese. The success of TPM, to a large extent, depends upon the success of AM.
Grinding machine is extensively used in the Machine Shop Laboratory, University Teknikal Malaysia Melaka (UTeM) to perform the task given especially in manufacturing practice subject. The machine is exposed to the breakdown as it is not well maintained. Maintenance and machine could not be separate to each other. Machine needs maintenance like human needs water. Daily maintenance, although it is simple but still could improve the effectiveness and expand the life time of the machine. This project will provide an organized methodology to perform AM on the grinding machine.
1.2 Objectives
The aims of this project are to:
1. Perform an AM programme on the grinding machine (Model: BO 300 A).
2. Identify and analyze the abnormalities on the grinding machine (Model: BO 300 A) and the remedies.
1.3 Scope
3
data sources. The project is started from December 2007 until April 2008. The result of this project may not applicable to other types of grinding machines or other machines.
1.4 Importance of Project
The importances of the project are to:
1. Promote the clean, neat and friendly workplace in FKP Machine Shop Laboratory.
2. Reduce the accident occurs in the FKP Machine Shop Laboratory.
3. Establish an orderly shop floor where any departure from normal conditions can be identified immediately.
4. Extends the machines life and improves availability and effectiveness.
5. Foster the development of knowledgeable students since most of the routine maintenance tasks are carried out by themselves.
6. As a reference for academic studies related to AM.
1.5 Outline of Report
The organization of this report is as follows:
Chapter 1 is the introduction of this project, describes the background and problem statement of the project. The objectives, scope, importance of the project and the project outlines are also presented in this chapter.
4
Chapter 3 is the literature review about grinding machine (Model: BO 300A), discusses about types of grinding machines, grinding wheels and cutting fluid. Besides, this chapter also explain about grinding machine (Model: BO 300 A) operation, safety and the machine troubleshooting.
Chapter 4 is the methodology, presents the appropriate methodology of this project. This chapter includes the project process planning, flowchart, Gantt chart, data gathering method and analytical which is includes Fuguai analysis.
Chapter 5 is the analysis and discussion, presents findings of the project. This chapter also discussed the autonomous steps that were carried out and shows the results obtained.
5
CHAPTER 2
MAINTENANCE
Chapter 2 presents the literature review regarding the definition, concept and evolution of maintenance and Total Productive Maintenance. Besides, characteristics of maintenance with description of types and six big loses are discussed. It is also includes the literature review regarding TPM Pillars, Overall Equipment Effectiveness, autonomous maintenance, and fuguai.
2.1 Introduction to Maintenance
Nowadays, organizations are under great pressure to enhance continuously their capability to create value to customers and improve the cost effectiveness of their operations (Campbell, 1995; Duffuaa and Al-Sultan, 1997; Shenoy and Bhadury, 1998; Tsang, 2002). In order to safeguard their performance, organizations need to formulate viable maintenance strategies and develop a fair measure of overall effectiveness aligning with industry's best practices (Al-Najjar, 1996).Once a system or a piece of equipment has been purchased, it must be maintained. The decisions made at purchasing always determine the type of future maintenance to be carried out (Levitt, 1997).
6
or restored to, a state in which it can perform its designated function (Duffuaa et al., 1999).
Willmott and McCarthy (2001), state that the definition of maintenance of a Japanese person from a world class manufacturing company as maintenance means maintaining and improving the integrity of our production and quality system through the machine, processes, equipment and people who add value to the products and services, that is the operators and maintenance of the equipment. Whereas, the maintenance definition to a typical Western manufacturing company as carry out planned servicing at fix intervals or fix it when it break down.
Maintenance can be defined most effectively by what it does, namely, the preservation or restoration of the desired function of a given process, at the lowest total cost (Narayan, 1998). Duffuaa et al. (1999) stated that maintenance as an integrated system that can provide a substantial edge in organization’s ability to be competitive and provide quality products or services. Whereas, according to Campbell et. al. (1999), maintenance is defined by which equipment or a system is kept in, or stored to, a state in which it can perform its designated functions.
