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© IMEC All rights reserved.
Roadmap to Maintenance 4.0
March 25, 2021
© IMEC All rights reserved.
© IMEC All rights reserved.
Technical Specialist
Jesse Brady
© IMEC All rights reserved.
AgendaCurrent StateEquipment EvaluationPM OptimizationTPM EventMetricsPredictive Maintenance TechniquesPrescriptive / Maintenance 4.0 Integration
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Current StateTypical conditions:
• Breakdowns occur regularly• Temporary repairs are the norm• There is often a run-to-failure mentality• Constant adjustments interrupt production • Minor stoppages occur frequently• Processing speed decreases • Equipment does not repeat• No one is accountable for tracking these losses• Operator training may not be adequate
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Equipment EvaluationSafetyProductionMaintenanceEquipment SystemsCritical Spare Parts
Equipment EvaluationEquipment Name Department
Equipment #/ID Location
Age
Score
1 <50%
3 50-80%
5 >80%
1 Yes
3 Yes, but some effort/disruption
5 No
1 Minimal
3 Some, but manageable
5 Profound
1 Minimal
3 Some or minor
5 Several or major
1 Yes and on hand
3 Yes, but none on hand
5 No
1 < 2 days
3 3-5 days
5 >5 days or unknown
1 Yes
3 Yes, but needs some work
5 No or ineffective
1 Spotless
3 Good, but needs some work
5 Needs a lot of work
1 Good
3 Minor work needed
5 Major work needed
1 Good
3 Minor work needed
5 Major work needed
1 Good
3 Minor work needed
5 Major work needed
1 Good
3 Minor work needed
5 Major work needed
1 Good
3 Minor work needed
5 Major work needed
1 Good
3 Minor work needed
5 Major work needed
1 Good
3 Minor work needed
5 Major work needed
Equipment Evaluation
Criteria
Production UtilizationPer month this machines
runs
Back upBack up equip or process
available
AffectAffect failure would
have on other processes
Maintenance Issues/DeficienciesDoes this equipment
have known deficiencies
Spare PartsCritical spare parts
identified
Lead TimeLead times for
spare/replacment parts
Safety GuardsMachine guards are in
place and functioning
Housekeeping Equip/area clean
Systems Condition Pneumatics
Hydraulics
Electrical
Lubrication
Motor/Drive
Cooling/Chilling
Mechanical
TPM Event
Asset Maintainable?
YES
NO
Maintain Equipment
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PM Optimization
Make it Specific Make it Visual Make it Repeatable
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Daily Operator PM Example
1. Check coolant level through clear Plexiglas
2. Check heat exchanger fans
(strings should be moving)
3. Check servo drive fans
(string should be moving)
4. Check heat exchanger air filter
(change when dark)
5. Check servo drive air filter
(change when dark)
6. Check way lube reservoir
(add when low)
7. Check main motor air filter
(change when dark)
8. Check main motor cooling fan
(string should move)
9. Check mist collector motor and air filter
(change when dark)
10. Check bar feeder hydraulic motor air filter
11. Check bar feeder hydraulic oil level
(add when low)
TPM Process
Deploy•5S and visual controls
•PM and checklists
•Problem solve
Document•History
•Lessons learned and best practices
•Communication board
Plan•Choose critical equipment
•Measure baseline
•Integrate business plan
•Create timetable
•Solicit champion
Evaluate•Check measurements
•Compare objectives
Establish MetricsCommon Maintenance Metrics• Maintenance Backlog• Meat Time To Repair (MTTR)• % Planned / Unplanned • Rework• Overall Equipment Effectiveness (OEE)
Identify Failure Points
39%24%
6%
16%15%
Running Time
Setup and Adjustment
Breakdowns
Idling and Minor Stoppages
Defects and Rework
OEE = 39%, Lost Capacity = 61%
Predictive Maintenance Techniques
• Vibration Analysis• Ultrasonic Analysis• Infrared Analysis• Oil Analysis• Lasor Alignment• Motor Circuit Analysis
Prescriptive / Maintenance 4.0 Integration
Industry 4.0 Technologies• IoT (Internet of Things)• Big Data• Cloud Computing
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ReviewCurrent StateEquipment EvaluationPM OptimizationTPM EventMetricsPredictive Maintenance TechniquesPrescriptive / Maintenance 4.0 Integration
