TPM 3 - Preventive Maintenance

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Preventive Maintenance
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Sensei Koichi Kimura:
Productive System), TQM, TPM (Total Productive and Total Preventive
Maintenance), Kaizen
introduction and fixing of these ones through personal growth and
assistance to the management for the change organization.
Sensei Koichi Kimura worked in Production Gemba for more than 45
years during which he devel
for Toyota, Honda, etc. in the hard and variable field of automotive
wiring systems in SUMITOMO Corp. from the position as a young
engineer, to even as General Manager passing throughout internal &
external consul
At time of publication and over the age of 74, he continues working on
the dissemination of original Japanese methods and more knowledge
even the one learned from the pioneers and, continues working as
international consultant for the last 22 years i
training clients, as a lecturer and writer. Even now, experimenting and
researching innovative methods and growing in the field of Production
Management and Corporate structuration.
- Koichi Kimura
NonCommercial-NoDerivatives 4.0 International License.
ttp://creativecommons.org/licenses/by-nc-nd/4.0/
Sensei Koichi Kimura:
Maintenance), Kaizen
years during which he devel
external consulting.
Koichi Kimura
NoDerivatives 4.0 International License.
nd/4.0/.
Sensei Koichi Kimura: International Consultant of the TPS (Total
and Factory Management. Expert in the
years during which he developed the JIT production system as supplier
International Consultant of the TPS (Total
oped the JIT production system as supplier
international consultant for the last 22 years in more than 11 countries,
Page
n more than 11 countries,
age 2 of 60

Total
El Documento ha sido editado para su impresión en Doble Cara sobre DIN
“Factory Management Institute”
publicación de este trabajo: 1 de Marzo 2018.
Nota Legal:
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Factory Management
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Nota Legal: Las marcas registradas mencionadas en este texto son propiedad de sus respectivos
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Haga clic en la im
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Factory Management
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https://jp.linkedin.com/in/kouichi
“Factory Management Institute” es una organización en período de constitución a la fecha de la
“Factory Management Institute” is an Organization in the Period of Incorporation at the date of
Las marcas registradas mencionadas en este texto son propiedad de sus respectivos
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Haga clic en la imagen para ver todas las lecturas del Factory Management Institute de Koichi Kimura,
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- Koichi Kimura
Factory Management - TPM Mantenimiento Preventivo Total. Volumen 3
Factory Management - TPM Total Preventive Maintenance. Volume 3
Koichi Kimura
Traducción, Edición y Adaptación de la versión Española:
es una organización en período de constitución a la fecha de la
is an Organization in the Period of Incorporation at the date of
agen para ver todas las lecturas del Factory Management Institute de Koichi Kimura,
cargada permanentemente y para siempre en Internet
Click on Image or Scan QR-code to see all Factory Management Institute Lecture by Koichi Kimura,
Koichi Kimura
nd/4.0/.
TPM Mantenimiento Preventivo Total. Volumen 3
TPM Total Preventive Maintenance. Volume 3
Koichi Kimura
Edition and Adaptation of the English version:
This Document has been edited to Double-Side Printing and DIN
publicación de este trabajo: 1 de Marzo 2018. www.factorymanagementinstitute.com
publication of this work: March, 1st
2018. www.factorymanagementinstitute.com
code to see all Factory Management Institute Lecture by Koichi Kimura,
permanentl
Título de la Versión
Mantenimiento Preventivo
Autor/Author:
Koichi Kimura – JAPÓN/JAPAN © 2018
https://jp.linkedin.com/in/kouichi-kimura
Eduardo L. García
https://es.linkedin.com/in/edulgg
Eduardo L. García
Side Printing and DIN
www.factorymanagementinstitute.com
permanently & forever uploaded into Internet
Page
Título de la Versión
Mantenimiento Preventivo
Title of English Version:
Autor/Author:
JAPÓN/JAPAN © 2018
kimura-2ba37152/en
Eduardo L. García – España © 2018
Eduardo L. García – Spain © 2018
El Documento ha sido editado para su impresión en Doble Cara sobre DIN-A4 + Encuadernación
Side Printing and DIN-A4 + Bookbinding
y & forever uploaded into Internet
age 3 of 60
Título de la Versión Española:
TPM Mantenimiento Preventivo Total. Volumen 3 -2018a
Mantenimiento Preventivo - PM
TPM Total Preventive Maintenance. Volume 3 -2018a
Preventive Maintenance - PM
Autor/Author:
JAPÓN/JAPAN © 2018
2ba37152/en
España © 2018
Spain © 2018
A4 + Encuadernación
A4 + Bookbinding
dueños.
cargada permanentemente y para siempre en Internet-Archive.org
y & forever uploaded into Internet-Archive.org
Española:
2018a
PM
2018a
PM
España © 2018
Spain © 2018
A4 + Encuadernación
A4 + Bookbinding
dueños.
Archive.org
Archive.org

Total
CONTENT
I. Introduction
II. TPM Checklist
III.
Breakdown maintenance;
Scheduled PM by special department or designated person;
Function Check PM;
Occasional PM;
The Machine Grave
IV.
Machine Ledger.
History of overhaul.
Overhaul annotation.
Preparation of overhaul.
History of (Regular) Inspection.
Regular Seiso.
Operator involvement.
Akafuda Tactics.
Control graphs of KPIs.
V. KPIs for PM
Statistical Quality control
QRQC & QRKA
Data Gathering
Backward Gathering (
CONTENT
Introduction
TPM Checklist
Activity of Special Department
Function Check PM;
Occasional PM;
The Machine Grave
The method of PM introduction
Machine Ledger.
Regular Seiso.
Akafuda Tactics.
KPIs for PM
Statistical Quality control
QRQC & QRKA
Data Gathering
Backward Gathering (
CONTENT
Introduction
TPM Checklist
Function Check PM;
Occasional PM;
The Machine Grave
Machine Ledger.
Regular Seiso.
Akafuda Tactics.
Statistical Quality control -
Data Gathering
Backward Gathering (⇐)
SQC
)
- Koichi Kimura
Koichi Kimura
nd/4.0/.
Pageage 4 of 60
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Forward Gathering (
The necessary level of Factor
VI.
VII.
1.-
Decide KPIs
Are KPIs no ne
2.-
3.-
1.
2.
3.
Why is the committee activity required?
4.-
Forward Gathering (
Jishu-Hozen
Introduction of TPM
- Decide KPIs in factory management.
Decide KPIs
DTO Rate
Are KPIs no ne
- Incorporation of these KPIs in management
- Establish KAIZEN committee in Gemba: 5Ss, Safety and Kaizen.
1.- Preparation step.
FIRST STEP:
SECOND STEP:
THIRD STEP:
FOURTH STEP:
The task of each subcommittee.
2.- Establishment step
The Members
Education
Training in each section
Making organization charts in each Gemba.
3.- Start and 5Ss activity by each group.
This is the story:
The conclusi
- Education & training and to transfer the SIMPLE MAINTENANCE JOB to Gemba.
Forward Gathering (⇒)
Hozen
Introduction of TPM
KPIs in factory management.
Are KPIs no necessary?
Incorporation of these KPIs in management
Establish KAIZEN committee in Gemba: 5Ss, Safety and Kaizen.
Preparation step.
FIRST STEP:
SECOND STEP:
THIRD STEP:
FOURTH STEP:
Establishment step
The Members
Education
Start and 5Ss activity by each group.
This is the story:
The conclusion of reasons:
Education & training and to transfer the SIMPLE MAINTENANCE JOB to Gemba.
The necessary level of Factory Management
on of reasons:
- Koichi Kimura
y Management
Koichi Kimura
nd/4.0/.
Page
age 5 of 60
28
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5.-
Skill level evaluation and incentive.
The method of evaluation
6.-
VIII.
QRQC & QRKA
Is it difficult to stop line?
So, What is Jidoka in TP
Looking at assembly line work.
Is Jidoka (QRQC & QRKA) difficult?
QRQC & QRKA in the concept of Jidoka.
Why implementation of QRQC & QRKA difficult?
Why do I describe QRQC & QRKA?
UPDATING TABLE:
Date, Version
- Skill Level Evaluation & Skill
- Transfer the additional simple maintenance job to Gemba.
JIDOKA
Toyota automatic loom example.
QRQC & QRKA
So, What is Jidoka in TP
UPDATING TABLE:
Date, Version-Previous è V
Skill Level Evaluation & Skill
Transfer the additional simple maintenance job to Gemba.
So, What is Jidoka in TPS?
UPDATING TABLE:
Previous è V-Next
Skill Level Evaluation & Skill level Table in Gemba.
S?
UPDATING TABLE:
Next Chapter (I..XX...)
- Koichi Kimura
level Table in Gemba.
UPDATING TABLE:
Chapter (I..XX...)
Koichi Kimura
nd/4.0/.
level Table in Gemba.
Chapter (I..XX...)
Chapter Point.
(Updating)
Page
Chapter Point.- sub-point :
(Updating)
age 6 of 60
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point :
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I.
Dear friends;
I would describe the story of PM (Preventive Maintenance).
Do you remember next diagram which is the frame of Factory Management?
And in this frame there is PM out of TPM & TPM.
PM is the important step of TPM, however, I willingly listed it out of TPM & TPM
of essential tool of basic factor
needs to have the system & capacity of PM for sound factory management.
1
First TPM is Total Preventive Maintenance. Second TPM is Total Productive Maintenance. Both concepts are introduced
the first volume of the Factory Management, TPM
Introduction
Dear friends;
you remember next diagram which is the frame of Factory Management?
Introduction
Introduction
of essential tool of basic factory management. Even not reached to the level of TPM, any factory
the first volume of the Factory Management, TPM -
- Koichi Kimura
y management. Even not reached to the level of TPM, any factory
- Volume 1.
Koichi Kimura
nd/4.0/.
Page
PM is the important step of TPM, however, I willingly listed it out of TPM & TPM1
. Because this is one
Koichi Kimura
February
age 7 of 60
Koichi Kimura
February-2018
First TPM is Total Preventive Maintenance. Second TPM is Total Productive Maintenance. Both concepts are introduced in
Koichi Kimura
2018
in

Total
product
to be necessary to produce and in the quantity to be necessary to produce”
“The purpose of the Total Preventive Maintenance is to maintain the
production ability to do the things to be necessary to produce, in the timing
- Koichi Kimura
ion ability to do the things to be necessary to produce, in the timing
Koichi Kimura
nd/4.0/.
Page
Koichi Kimura
age 8 of 60
Koichi Kimura
Koichi Kimura

Total
II.
For your good understanding, and before going to the main theme, I present a che
Please check your company's TPM capacity throughout this checklist is constructed in 4 categories,
which are:
1.
2.
3.
4.
And, totally 80 questions. This is just a game, so p
First 1. is the results of TPM activity. And the items of 2, 3 and 4 are the causes or the necessary
conditions to 1.
Therefore for good results (12 checkpoints), other 68 items are essential. As total and if you could
gain more tha
And total good results, however if the score is poor in first 1 items and good score of 2, 3 and 4
items, it shows something wrong. Then it must be recommendable to review in hu
TPM Checklist
which are:
1. As the result.
2. Machine condition.
3. Factory Management. And
4. Operator Capacity.
conditions to 1.
gain more than 80% your factory is ordinal as the factory who gained the capacity of TPM.
TPM Checklist
As the result.
Machine condition.
Factory Management. And
Operator Capacity.
n 80% your factory is ordinal as the factory who gained the capacity of TPM.
TPM Checklist
Factory Management. And
- Koichi Kimura
And, totally 80 questions. This is just a game, so please, do comfortably.
Koichi Kimura
nd/4.0/.
lease, do comfortably.
lease, do comfortably.
Page
For your good understanding, and before going to the main theme, I present a checklist as next.
items, it shows something wrong. Then it must be recommendable to review in humble way.
age 9 of 60
cklist as next.
mble way.

Total
- Koichi Kimura
Koichi Kimura
nd/4.0/.
“Data and Sashimi; the fresher, the better”.”
Page
Koichi Kimura
age 10 of 60
Koichi Kimura
Koichi Kimura

Total
Now Preventive Maintenance (PM), which is the main theme of this column.
In PM I need to write following 2 contents:
1.
2.
III.
There are several kinds of maintenance activities.
Which is mainly repair activity after breakdown. It is most primi
reliability. Of course it is very bad cost performance in total
This is a scheduled preventive activity. And, the engineers inspect and maintain following
irregularities.
●
●
●
The 2 steps description: As you aware above inspection items are written in 2 steps. From Electric
system up to Crack are required some kind of spec
equipment.
●
2
Some author calls it as “Reactive Maintenance”.
3
NT: PREVENTIVE vs. PREDICTIVE: Master Koichi Kimura, includes in this section what in the West Countries is,
perhaps wrongly, known as Predic
Maintenance to what the thought transmitted by Master Koichi Kimura considers exclusively Preventive
Maintenance. The technology and approach that is used to prevent the breakdown is ind
ultimate purpose. This is, in the eyes of the Sensei, the same Prevention activity. For example, the possible
breakage of an axis by means of an analysis of the vibrations or, the overheating of an electrical
1. One is the Activity of Special
2. Another is
regularities.
● Electric system, Air system, Sensor, Shaft bearing, Gearing,
● Rotating system, Control box, Hydraulic system, Crack.
● And next other issues: Oil system, Abnormal movement, Vibration, V
Looseness, Rattle, Heat, Wear, Shake, Lea
Chips, Falling out, Trash, Dirty, Rust, Scar, Breakage.
equipment.
● FIRST STEP
Frequency characteristic measuring device. Thyristor
device3
. Etc.
One is the Activity of Special
Another is Jishu-Hozen
Electric system, Air system, Sensor, Shaft bearing, Gearing,
Rotating system, Control box, Hydraulic system, Crack.
And next other issues: Oil system, Abnormal movement, Vibration, V
FIRST STEP -Special equipment
. Etc.
One is the Activity of Special Department (III).
Hozen: Autonomous Maintenance, by operator (IV).
Special equipment-:
perhaps wrongly, known as Predictive Maintenance. In the West Countries we have considered Predictive
- Koichi Kimura
Department (III).
: Autonomous Maintenance, by operator (IV).
Looseness, Rattle, Heat, Wear, Shake, Leak, Scattering, Abnormal smell, Noise, Discolouring,
system up to Crack are required some kind of special knowledge and moreover, about special
For instance; Automatic insulation diagnostic equipment.
tive Maintenance. In the West Countries we have considered Predictive
Koichi Kimura
nd/4.0/.
Department (III).
Which is mainly repair activity after breakdown. It is most primitive and the production process is low
reliability. Of course it is very bad cost performance in total2
.
k, Scattering, Abnormal smell, Noise, Discolouring,
ial knowledge and moreover, about special
Frequency characteristic measuring device. Thyristor-Tracer. Rotating equipment diagnostic
tive and the production process is low
And next other issues: Oil system, Abnormal movement, Vibration, V-
Tracer. Rotating equipment diagnostic
Page
-belt, Bend, Tilt,
Maintenance. The technology and approach that is used to prevent the breakdown is independent of its
breakage of an axis by means of an analysis of the vibrations or, the overheating of an electrical-electronic
age 11 of 60
belt, Bend, Tilt,
ependent of its
electronic

Total
●
Function Check PM;
It is one function of machine deteriorates over time. It is quite natural phenomenon. This issue is
checked in a
function from the point of quality and output capacity.
The chance of this implementation is the voice of Gemba. When getting the voice of Gemba such as:
This phenomenon is not categorised in breakdown or machine trouble in Gemba. And, Gemba also
thinks that it is necessary to master in the name of "skill". But the Gemba
maintenance engineer must never miss to hear such voice. And a machinery performance graphs and
kaizen suggestions are also important Gemba voice.
Occasional PM;
One machine maintenance engineer is required to attend to the 3 important mont
occasional quality meeting, customer's concern review meeting and safety (accident) meeting. The
three monthly review meeting: Production, Quality and Management meeting
element with a therm
Maintenance. The usefulness of this prediction is to know how much time we have to repair the element and
study the reasons for this failure (many times we do not make the stud
at a level that allows its using for a limited time.
ISO TS / 16946 / IATF 16949: 2016: Regarding the quality standards applicable to, for example, the automotive
industry; Clause 7.5.1.4 of the IATF standard or ISO
a strategy of Preventive and Predictive Maintenance, identifying the key equipment of the process and having
the appropriate elements for maintenance and using maintenance methods Predictive (Predict
- PdM) to improve continuously.
In this way, the regulation establishes the need for Preventive Maintenance and defines it as based on TIME.
However, the Predictive Maintenance, according to the norm, is based on the CONDITION. On the other
Predictive checking is usually done at time intervals, so the differentiation between Predictive (based on
condition) and Preventive (based on time) is not considered necessary for Master Koichi Kimura.
ISO/TS or IATF 16949 would define the First st
correspond to the
● SECOND ST
senses of operator. Then these are possible to be delegated to Gemba peoples to find the
abnormalities. And an operator needs to identify the abnormalities and inform to
maintenan
themselves in proper training and education.
Function Check PM;
checked in above Scheduled PM. And on the other hand it is quite recommendable to check the
"Became to be difficul
"Became to occur defects in standard speed", etc.
Occasional PM;
element with a therm
PdM) to improve continuously.
correspond to the Preventive Maintenance
SECOND STEP -From Oil system to Breakage
maintenance engineer. And some of these abnormalities are possible to be coped with by
Function Check PM;
bove Scheduled PM. And on the other hand it is quite recommendable to check the
"Became to be difficul
Occasional PM;
element with a thermographic camera is classified, according to the western approach, as Predictive
From Oil system to Breakage
ce engineer. And some of these abnormalities are possible to be coped with by
Function Check PM;
"Became to be difficult to adjust the necessary condition"
ographic camera is classified, according to the western approach, as Predictive
Preventive Maintenance in that standard.
- Koichi Kimura
From Oil system to Breakage-
t to adjust the necessary condition"
industry; Clause 7.5.1.4 of the IATF standard or ISO/TS 16949: 2016 establishes the requirement to implement
ISO/TS or IATF 16949 would define the First step (1) as Predictive Maintenance
in that standard.
Koichi Kimura
nd/4.0/.
-: There are possible to diagnose in mainly 5
study the reasons for this failure (many times we do not make the study), which is already occurring, although
/TS 16949: 2016 establishes the requirement to implement
Predictive Maintenance
in that standard.
There are possible to diagnose in mainly 5
thinks that it is necessary to master in the name of "skill". But the Gemba supervisor and
y), which is already occurring, although
Predictive Maintenance and the Second step (2) would
Page
supervisor and
One machine maintenance engineer is required to attend to the 3 important monthly meeting and
the appropriate elements for maintenance and using maintenance methods Predictive (Predictive Maintenance
and the Second step (2) would
age 12 of 60
supervisor and
hly meeting and
ive Maintenance
However, the Predictive Maintenance, according to the norm, is based on the CONDITION. On the other hand,
and the Second step (2) would
ive Maintenance

Total
When occurring quality problems, maintenance engineer should attend t
point of view of machine, maintenance engineer is required to review the problem and find the
countermeasures. And taking advantage of this opportunity, maintenance engineer is required the
countermeasures of machinery defect and a
A company is required to have the organization of Special Department of machinery maintenance.
And whether the company were small, at least machine maintenance responsible person should be
designated and registered to respon
Is it necessary to have an organization or such person registered, even if the company were small?...
The answer is “Yes”, even though a very small company it is necessary to have such function. In this
regard, I tell a sto
One day I have been invited to visit very small company who has 3 machineries by a machine
maker. Then, after looking the small factory, I questioned to the president.
― Who can maintain the machineries? and, when machine trouble occurred, who i
the machines?
― I can maintain the machines ―he said.
After the visit and when coming back to my hotel, the machine
follow.
― This company is a good customer, because he is rich and when machine would b
same machine from my company. There were such cases within several years.
― To buy a replacement? ...Same machine within several years!? ―I asked, a li le surprised.
― Moreover my engineer is required to run to repair the machines with ur
the sales manager ―. Of course we oﬀer the maintenance training with cheaper price. But the owner
president told us to be no necessary.
It is quite true that his maintenance activity is not sufficient. No, I mistook. He has neithe
maintenance system nor the capacity.
Actually he has another one small structure housing for machines. It is, or we call as "
machines
Now there are some wr
― We get an urgent call from this company. And, a er the inspec on of my engineer, he starts to
repair the machine troubled ―the sales manager men oned and con nues―, and when ﬁnding the
lack of necessary parts, he goes to this machine grave and takes
So, at a later date. This company made a new contract regarding Scheduled PM with this Machine
tool maker.
regard, I tell a sto
the machines?
follow.
machines". In fact, through his conversation I learned the word of "
Now there are some wr
tool maker.
regard, I tell a story...
". In fact, through his conversation I learned the word of "
Now there are some wrecks of machines in that structure housing and it happens as next…
designated and registered to respond above 4 types of maintenances.
ecks of machines in that structure housing and it happens as next…
- Koichi Kimura
countermeasures of machinery defect and also, some function improvement.
d above 4 types of maintenances.
Koichi Kimura
nd/4.0/.
lso, some function improvement.
After the visit and when coming back to my hotel, the machine-tool maker sales manager told me as
lack of necessary parts, he goes to this machine grave and takes some parts from the wrecks.
When occurring quality problems, maintenance engineer should attend the meeting. And from the
tool maker sales manager told me as
― Moreover my engineer is required to run to repair the machines with urgent spare parts. ― said
". In fact, through his conversation I learned the word of "grave of machines
some parts from the wrecks.
Page
he meeting. And from the
― Who can maintain the machineries? and, when machine trouble occurred, who inspect and repair
― This company is a good customer, because he is rich and when machine would break, he buys
gent spare parts. ― said
It is quite true that his maintenance activity is not sufficient. No, I mistook. He has neither necessary
Actually he has another one small structure housing for machines. It is, or we call as "grave of
grave of machines".
age 13 of 60
he meeting. And from the
One day I have been invited to visit very small company who has 3 machineries by a machine-tool
nspect and repair
reak, he buys
gent spare parts. ― said
r necessary
grave of
So, at a later date. This company made a new contract regarding Scheduled PM with this Machine-

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TPM 3 - Preventive Maintenance

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