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UNIVERSITI TEKNIKAL MALAYSIA MELAKA Study the Process of Total Preventive Maintenance (TPM) of Injection Moulding Machine Arburg 420C Thesis submitted in accordance with the requirements of the Universiti Teknikal Malaysia Melaka for the Degree of Bachelor of Engineering (Honors) Manufacturing (Process) By HIDAYATULLAH BIN MUSA Faculty of Manufacturing Engineering March 2008

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Page 1: UNIVERSITI TEKNIKAL MALAYSIA MELAKA - …eprints.utem.edu.my/6344/1/Study_The_Process_Of_Total_Preventive... · Tesis adalah hak milik Universiti Teknikal Malaysia Melaka. 2. Perpustakaan

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

Study the Process of Total Preventive

Maintenance (TPM) of Injection Moulding

Machine Arburg 420C

Thesis submitted in accordance with the requirements of the Universiti Teknikal

Malaysia Melaka for the Degree of Bachelor of Engineering (Honors)

Manufacturing (Process)

By

HIDAYATULLAH BIN MUSA

Faculty of Manufacturing Engineering

March 2008

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UTeM Library (Pind.1/2005)

UNIVERSITI TEKNIKAL MALAYSIA MELAKA (UTeM)

BORANG PENGESAHAN STATUS TESIS*

JUDUL: STUDY THE PROCESS OF TOTAL PREVENTIVE MAINTENANCE (TPM) OF INJECTION MOULDING MACHINE ARBURG 420C

SESI PENGAJIAN: 2007/2008 Saya HIDAYATULLAH BIN MUSA 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. 4. **Sila tandakan (√)

SULIT

TERHAD

TIDAK TERHAD

(Mengandungi maklumat yang berdarjah keselamatan 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)

Alamat Tetap: Kg Bukit Cina, Wakaf Mesira, 21060 Kuala Terengganu, Terengganu Darul Iman. Tarikh:

Disahkan oleh:

(TANDATANGAN PENYELIA)

Cop Rasmi:

Tarikh: * 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.

25/03/2008

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APPROVAL

This thesis submitted to the senate of UTeM and has been accepted as partial

fulfillment of the requirements for the degree of Bachelor of Manufacturing Engineering

(Manufacturing Process). The members of the supervisory committee are as follow:

………………………………………….

Supervisor

(Official Stamp & Date)

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DECLARATION

I hereby, declare this thesis entitled “Study the process of Total Preventive Maintenance

(TPM) of Injection Molding Machine Arburg 420C” is the result of my own research

except as cited in the reference.

Signature : ………………………………………….

Author Name : …………………………………………

Date : …………………………………………

HIDAYATULLAH BIN MUSA25TH March 2008

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ABSTRACT

This project describes about the application of Total Preventive Maintenance (TPM) on

the Injection Molding Machine. As a preference, this project has be held in the Casting

Laboratory in Universiti Teknikal Malaysia Melaka (UTeM) located in Fasa B. The type

of machine used in this research is the Arburg 420C Injection Molding Machine. The

purpose of this research is to obtain the best way to perform the maintenance method for

the Arburg 420C Injection Molding Machine using the TPM method. By combining two

tools of total preventive maintenance which was based on time and based on machine,

the project has been achieved by doing internal maintenance and external maintenance

of that machine. The maintenance of the machine has been done according to daily,

weekly, monthly and yearly. Research has been done before and after the machine was

used. At the end of this project, the maintenance application was used which the TPM

has been documented and recorded based on standard as reference later. Thus, the TPM

keep the Injection Molding Machine more cleanly, clearly, equipments and facilities

will be systematic arrangement efficient and effective. Therefore, TPM makes the

machine always in good condition and preventing the machine becomes breakdowns.

i

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ABSTRAK

Projek ini akan memperihalkan kajian tentang aplikasi Penyelenggaraan Pencegah

Keseluruhan (PPK) terhadap Mesin Acuan Suntik. Secara amnya, projek ini telah

dijalankan di Makmal Tuangan Universiti Teknikal Malaysia Melaka (UTeM) yang

terletak di kompleks Fasa B. Jenis mesin yang terlibat di dalam projek ini adalah Mesin

Acuan Suntik jenis Arburg 420C. Tujuan projek ini dijalankan adalah untuk

mendapatkan ataupun mengetahui cara yang terbaik untuk menyelenggara Mesin

Acuan Suntik Arburg 420C menggunakan kaedah Penyelenggaraan Pencegah

Keseluruhan. Projek penyelenggaraan ini telah menggabungkan kedua-dua kaedah

Penyelenggaraan Pencegah Keseluruhan iaitu berdasarkan mesin dan berdasarkan masa.

Selain itu, projek ini dijalankan untuk mengenalpasti komponen-komponen yang perlu

diselenggara mengikut hari, minggu, bulan dan tahun. Disamping itu juga, projek ini

telah dilakukan sebelum, semasa dan selepas operasi mesin ini dijalankan untuk

mengetahui masalah-masalah yang timbul yang berkaitan dengan penyelenggaraan

mesin tersebut. Pada akhir projek ini, ianya menjangkakan bahawa segala informasi,

masalah dan kaedah yang digunakan semasa projek dijalankan akan direkodkan

mengikut piawaian untuk penggunaan pada masa hadapan. Projek ini telah didedahkan

kepada aplikasi-aplikasi yang telah dipelajari sebelum ini seperti kaedah dalam

Penyeleggaraan Pencegah Keseluruhan dan penggunaan Mesin Acuan Suntik secara

praktikal. Maka, dengan mengunakan kaedah Penyelenggaraan Pencegah Keseluruhan,

keadaan mesin akan menjadi semakin baik, bersih dan selamat. Kerana itu, dapat

mecegah mesin daripada rosak terlebih awal.

ii

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DEDICATION

For my supervisor, lecturers, family and friends

iii

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ACKNOWLEDGEMENTS

Assalamualaikum w.b.t. and warm greeting,

First of all, thank to ALLAH SWT for His blessings and for the strength given to me to

finish this Projek Sarjana Muda.

I would like to extend my heartfelt gratitude to all that have been contributed to the

success of this Projek Sarjana Muda. I wish to acknowledge and express my gratitude

and appreciation to my supervisor, Mr. Mohd Amran b. Md Ali for his supervision,

encouragement, suggestion and assistance through the research.

I also would like to convey my biggest thanks to Faculty of Manufacturing Engineering

(FKP) especially Professor Dr. Mohd Razali b. Muhamad, Dean of Faculty of

Manufacturing Engineering (UTeM) Mr Mohd Hadzley b. Abu Bakar and all the

lectures in the faculty.

It is a pleasure for me to express huge gratitude to Mr. Nor Fauzi b. Tamin, the technical

staff who construct and guide through completing this research while conducting the

maintenance process in Casting Laboratory as his kindness and willing really regards

me with pleasure. I could offer here only an inadequate gesture of my appreciation and

all of your good deeds will always be in my mind.

iv

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TABLE OF CONTENT

Abstract .............................................................................................................................i

Abstrak………………………………………………………………………………...…ii

Dedication ........................................................................................................................iii

Acknowledgement ............................................................................................................iv

Table of Contents ..............................................................................................................v

List of Figures ..................................................................................................................ix

List of Table ......................................................................................................................x

List of Abbreviations, Symbols and Specialized Nomenclature ......................................xi

1. INTRODUCTION .......................................................................................................1

1.1 Background ..............................................................................................................1

1.2 Problems Statements ...............................................................................................2

1.3 Objectives ………………........................................................................................3

1.4 Scope ………………………………………………………………………... …....3

2. LITERATURE REVIEW ...........................................................................................4

2.1 Introduction .............................................................................................................4

2.2 Introduction to Engineering Maintenance……………………..…………………..4

2.2.1 History of Maintenance ..................................................................................5

2.2.2 Maintenance Engineering Objectives .............................................................6

2.2.3 Facts Related to Engineering Maintenance ....................................................6

2.2.4 Safety in Maintenance.....................................................................................7

2.2.5 Quality in Maintenance ..................................................................................8

2.2.6 Maintenance Mission.....................................................................................10

2.2.7 Maintenance Challenge.................................................................................12

2.2.8 Changing World of Maintenance..................................................................14

2.2.8.1 Research............................................................................................15

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2.2.8.2 New Techniques................................................................................15

2.2.8.3 Challenges Facing Maintenance Personal.........................................16

2.3 Introduction of Total Preventive Maintenance.......................................................16

2.3.1 Application of Total Preventive Maintenance...............................................17

2.3.2 Total Preventive Maintenance Objective......................................................18

2.3.3 Preventive Maintenance Components and Principle for

Choosing Items for Preventive Maintenance................................................18

2.3.4 Step for Developing Preventive Maintenance Program................................19

2.3.5 Preventive Maintenance Benefit and Drawbacks..........................................20

2.4 Introduction of Injection Molding..........................................................................21

2.4.1 Injection Molding Process.............................................................................21

2.4.2 Injection Molding Machine...........................................................................22

2.4.3 Types of Injection Molding Machines Components.....................................23

2.4.4 Types of Injection Molding System..............................................................26

2.5 Human Error in Engineering Maintenance.............................................................28

2.5.1 Maintenance Error-Related Facts and Figures..............................................28

2.5.2 Reasons for Human Error in Maintenance....................................................29

2.5.3 Major Human Failures in Maintenance and Classification

of Maintenance Errors and Their Occurrence Frequency.............................30

2.5.4 Useful Guidelines for Reducing Maintenance Errors...................................31

2.5.4.1 Design................................................................................................32

2.5.4.2 Tools and Equipment.........................................................................32

2.5.4.3 Procedures.........................................................................................32

2.5.4.4 Training.............................................................................................33

2.5.4.5 Maintenance Incident Feedback........................................................33

2.5.4.6 Supervision........................................................................................33

2.5.4.7 Communication.................................................................................34

2.5.4.8 Shift Handover...................................................................................34

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3. METHODOLOGY ....................................................................................................35

3.1 Introduction ...........................................................................................................35

3.2 Project Selection ....................................................................................................37

3.4.1 Selection of machine.....................................................................................37

3.4.1 Selection of experiment method....................................................................38

3.3 Discuss detail plan and conduct preliminary research...........................................38

3.4 Study of fundamentals of Total Preventive maintenance.......................................38

3.5 Design and apply the method of Total Preventive Maintenance............................39

3.6 Document the Maintenance Procedures (ISO) ......................................................40

3.7 Implement of Total Preventive maintenance..........................................................41

3.8 Analyze the component that has been maintenance ..............................................42

3.9 Discussion, Conclusion and Recommendations.....................................................42

4. FINDING OF TOTAL PREVENTIVE MAINTENANCE …………….………..43 4.1 Introduction………………………………………………………………….…....43

4.2 Restoration Equipment………………………...………………………………….43

4.2.1 Procedures to Switch ON the Plastic Injection Molding Machine………….44

4.2.2 Procedures to operate the Plastic Injection Molding Machine……………...44

4.2.2.1 Manual Mode………………………………………………………..44

4.2.2.2 Automatic Mode…………………………………………………….45

4.2.3 Procedures to Switch OFF the Plastic Injection Molding Machine…...……45

4.2.4 Safety Precaution……………………………………………………………46

4.2.4.1 Safety Instruction Before Operating Injection Molding Machine…..46

4.2.4.2 Safety Instruction While Operating Injection Molding Machine…...47

4.2.4.3 Safety Instruction After Operating Injection Molding Machine……47

4.3 Eliminate Contamination and Stains on Area and Machine………………………47

4.4 Improve Equipment Accessibility………………………………………………...51

4.5 Preventive Maintenance for Arburg 420C Injection Molding Machine………….53

4.5.1 Arburg 420C Injection Molding Machines Maintenance Plan Standards…..55

4.5.2 Troubleshooting and Maintenance………………………………………….59

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5. DISCUSSION………………………………………………………………………..62 5.1 Introduction………………………………………………………………….…....62

5.2 Quality Improvement.......................................................................................…....62

5.3 Safety Guaranteed……………………………………………………...…………63

5.4 TPM Effectiveness………………………………………………………………..64

5. CONCLUSION AND………………………….……………………………….…...65 5.1 Conclusion ……………………………………….………………………….…....65

5.2 Recommendations...........................................................................................…....66

REFERENCES ..............................................................................................................67

APPENDICES

A Gantt chart (PSM 1)

B Gantt chart (PSM 2)

C Specification of the Arburg 420C

D Maintenance Plan Schedule

E Maintenance of the Oil Cooler and Filter

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LIST OF FIGURES

2.1 Important objectives of maintenance engineering..................................................6

2.2 Important benefits of performing preventive maintenance..................................20

2.3 Injection machine unit..........................................................................................23

2.4 A reciprocating screw, showing the feeding zone, compressing

(or transition) zone, and metering zone................................................................24

2.5a Nozzle with barrel in processing position............................................................25

2.5b Nozzle with barrel backed out for purging...........................................................25

2.6 The molded system includes a delivery system and molded parts.......................27

2.7 Some of the important reasons for the human error in maintenance....................30

3.1 Process planning of the project.............................................................................36

3.2 Arburg 420C injection molding machine.............................................................37

3.3 Flow chart of documented procedures (ISO) of the project.................................40

3.4 Flow chart of implement total preventive maintenance of the project.................41

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LIST OF TABLES

4.1 Eliminate contamination and stains on area and machine activities……………48

4.2 Eliminate contamination and stains on area and machine activities……………49

4.3 Eliminate contamination and stains on area and machine activities……………50

4.4 Eliminate contamination and stains on area and machine activities……………51

4.5 5’S activities…………………………………………………………………….52

4.6 Machine Maintenance Schedule………………………………………………...54

4.7 Plastic Injection Plan Maintaining………………………………………………55

4.8 Troubleshooting and Maintenance……………………………………………...59

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LIST OF ABBREVIATIONS, SYMBOLS, SPECIALIZED

NOMENCLATURE

CAM - Computer Aided Manufacturing

CM - Corrective Maintenance

CBP - Current Best-Practice

mm - Millimeter

min - Minute

FKP - Faculty of Manufacturing Engineering

FMEAs - Failure modes and effects analyses

FTM - Fixed-Time Maintenance

PM - Preventive Maintenance

PMT - Post Maintenance Testing

rpm - Revolution per minute

TPM - Total Preventive Maintenance

TQM - Total Quality Management

US - United States

UTeM - Universiti Teknikal Malaysia Melaka

µm - Micrometer

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CHAPTER 1 INTRODUCTION

1.1 Background

In this study, it is clearly shown that the conditions of machine are the important term in

manufacturing industry. Proper hands-on maintenance techniques provide increased

reliability and uptime for our injection molding machines. The common focus of this

study is changed from fixing breakdowns machines to preventing them. The benefits of

Total Preventive Maintenance (TPM) come when companies transition from a fire-

fighting mode of fixing one sudden breakdown after another to preventing those

breakdowns.

The research of this study involved the fundamentals of maintenance of Arburg 420C

injection machine and the process which are related to the TPM concept. The main

focus of this study is focuses on TPM of Arburg 420C injection molding machine. The

propose of this research is on the aspect need on maintenance of injection molding

machine such as daily maintenance, weekly maintenance, monthly maintenance and

annually maintenance.

Universiti Teknikal Malaysia Melaka (UTeM) as a university technical was establish

since 2001 which involve in manufacturing also has use the Injection molding machine.

There are a injection molding machine model Arburg 420C has located at Casting

Laboratory at FKP laboratory since establish. Here the student will operate this machine

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theirself with observation and guide by technician. Students from first years till last year

were use the injection molding machines in their course, so the frequency of use this

machine is very high. In this situation, the maintenance action is very important to avoid

the breakdown problem from happened to the machine. There have Preventive

Maintenance, Breakdown Maintenance and Corrective Maintenance had been

implement in this lab, but the shown the poor result of maintenance and not implement

systematic. So the solution is to implement of TPM programme to the Arburg 420C

injection molding machine at casting laboratory. This project will define TPM in some

detail, evaluate its strengths and weaknesses as a maintenance philosophy, and discuss

implementation procedures. Examples of successfully implemented programs will be

presented.

1.2 Problem Statement

Nowadays many of injection companies do not have proper scheduling of maintenance

on their factories. This situation will lead cost of maintenance system of injection

machine will be increase. Some of company have maintenance system but do not

document properly the maintenance documentation. Maintenance of related equipment

such as cruncher, water cooling machine and material feeding also will increase the

maintenance cost.

Preventive maintenance brings maintenance into focus as a necessary and vitally

important part of the company. It is no longer regarded as a non-profit activity. Down

time for maintenance is scheduled as a part of the manufacturing day and in some cases

as an integral part of the manufacturing process. It is no longer simply squeezed in

whenever there is a break in material flow. The goal is to hold emergency and

unscheduled maintenance to a minimum.

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Today, with competition in industry at an all time high, TPM may be the only thing that

stands between success and total failure for some companies. It has been proven to be a

program that works. It can be adapted to work not only in industrial plants, but in

construction, building maintenance, transportation, and in a variety of other situations.

1.3 Objective The aim of this project was to study the process of Total Preventive Maintenance (TPM)

of injection machine Arburg 420C. The main objectives were:

1. To find out the proper way of Total Preventive Maintenance (TPM) on Arburg

420C injection machine.

2. To documented a daily, weekly, monthly and annually maintenance.

3. To investigate before, during and after operation maintenance.

1.4 Scope

This study focuses on the concept of Total Preventive Maintenance of Arburg 420C

injection machine. Besides that, this project also will study what aspect need on

maintenance of injection machine. The aspect of maintenance such as a daily

maintenance, weekly maintenance, monthly maintenance and annually maintenance will

be investigated.

During the research, the maintenance process which is will be done before, during, and

after operated of injection machine will be investigated also. The related equipment of

the injection machine such as cruncher, water cooling machine and blower of feeding

system also will be focuses and study.

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CHAPTER 2 LITERATURE REVIEW

2.1 Introduction

This literature review discusses thoroughly on the issue that is related with the Total

Preventive Maintenance in manufacturing industry. The legal requirement regarding the

Total preventive Maintenance is stated in this part and explains further on what is the

preventive maintenance how important the factor to be controlled the maintenance

process in machining operation. The other related topic is about the maintenance

overview, injection molding machine and the others factor that related the maintenance

operation. Here in this literature review also review the other method and techniques

which used in the preventive maintenance and also the development and the challenge

of the preventive maintenance in industry nowadays.

2.2 Introduction to Engineering Maintenance

Each year billons of dollars are spent on engineering equipment maintenance

worldwide, and today’s maintenance practices are market driven, in particular for the

manufacturing and process industry, service suppliers, and so on [1]. Because of this,

there is a definite need for effective asset management and maintenance practices that

can positively influence success factors such as price, profitability, quality, reliable

delivery, safety, and speed of innovation.

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In the future engineering equipment will be even more computerized and complex.

Further computerization of equipment will increase the importance of software

maintenance significantly, approaching, if not equaling hardware maintenance. In

addition, factors such as increased computerization and complexity will result in greater

emphasis on maintenance activities with respect to areas such as cost effectiveness,

quality, safety, and human factors [2]. In the future creative thinking and new strategies

will definitely be required to realize all potential benefits and turn them into

profitability.

2.2.1 History of Maintenance

Although humans have felt the need to maintain their equipment since the beginning of

time, the beginning of modern engineering maintenance may be regarded as the

development of the steam engine by James Watt (1736-1819) in 1769 in Great Britain

[4]. In the United States the magazine Factory first appeared in 1882 and has played a

pivotal role in the development of the maintenance field [3]. In 1886 a book on

maintenance of railways was published [5].

In the l950s the term preventive maintenance was coined, and in 1957 a handbook on

maintenance engineering was published [6]. Over the years many other developments in

the field of engineering maintenance have taken place, and today many universities and

other institutions offer academic programs on the subject.

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2.2.2 Maintenance Engineering Objectives

There are many objectives of maintenance engineering. Some of the important ones as

shown in Figure 2.1 [7].

Figure 2.1: Important objectives of maintenance engineering.

2.2.3 Facts Related to Engineering Maintenance

Some of the facts and figures concerning engineering maintenance are as follows:

1. U.S. industry spends over $300 billion annually on plant maintenance and

operations [8].

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2. It is estimated that the cost of maintaining a military jet aircraft is approximately

$1.6 million per year, and about 11% of the operating cost for an aircraft accounts

for maintenance activities [9].

3. Over the years the size of a plant maintenance group in a manufacturing

organization has varied from 5 to 10% of the total operating force [10] — 1 to 17

persons in 1969 and 1 to 12 persons in 1981 [10].

4. For fiscal year 1997, the request of the U.S. Department of Defense for their

operation and maintenance budget was $79 billion [11].

5. In 1970 a British Ministry of Technology Working Party document reported that the

United Kingdom annual maintenance cost was around 3000 million pounds [12,13].

6. The U.S. Department of Defense spends approximately $12 billion annually on

depot maintenance of weapon systems and equipment [14].

2.2.4 Safety in Maintenance

Safety in maintenance is becoming an important issue, as accidents occurring during

maintenance work or concerning maintenance are increasing significantly. For example,

in 1994 around 13.61% of all accidents in the U.S. mining industry occurred during

maintenance work and they have been increasing at a significant rate annually since

1990 [15,16].

Some of the main reasons for safety problems in maintenance are poor safety standards

and tools, poor equipment design, poor training of maintenance personnel, insufficient

time to perform required maintenance tasks, poorly written maintenance instructions and

procedures, poor management, poor work environments, and inadequate work tools[16].

One of the important ways to improve maintenance safety is to reduce the requirement

for maintenance as much as possible in products and systems during their design phase.

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When the need for maintenance cannot be avoided, designers should follow guidelines

such as those listed below for improving safety in maintenance [17]:

1. Eradicate the need for performing maintenance and adjustments close to

hazardous operating parts or equipment.

2. Keep design as simple as possible, because complexity usually adds to

maintenance problems.

3. Aim to eliminate the requirement for special tools or equipment.

4. Provide appropriate guards against moving articles or parts and interlocks for

blocking accesses to hazardous locations.

5. Incorporate appropriate fail-safe designs for preventing injury and damage if a

failure occurs.

6. Design for easy accessibility so that items requiring maintenance can easily be

checked, removed, replaced, or serviced.

7. Develop designs or procedures that minimize the occurrence of maintenance

errors.

8. Develop the design in a manner that reduces the probability of maintenance

personnel being injured by escaping high-pressure gas, electric shock, contact

with a hot surface, and so on.

9. Incorporate appropriate devices or other measures for early prediction and

detection of all potential failures so that the required maintenance can be

performed prior to failure with somewhat reduced risk of hazard.

2.2.5 Quality in Maintenance

Maintenance quality provides some degree of confidence that repaired or maintained

items will function safely and reliably [18,19]. Quality in maintenance is very important

because poor quality maintenance can lead to severe consequences. For example, the

following three tragedies are believed to be, directly or indirectly, the result of poor

quality maintenance [16]:

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1. In 1986 the space shuttle Challenger exploded and all seven crew members lost

their lives [18,19]. A subsequent investigation identified the cause of the disaster

as the failure of the pressure seal in the aft field joint of the right solid rocket

motor. Furthermore, the investigation concluded that a high-quality maintenance

program would have successfully tracked and discovered the cause of the

disaster.

2. In 1990 10 people died as the result of a serious steam leak in the fire room on

the U.S.S. Iwo Jima (LPH2), a U.S. Navy ship [20]. Failure of the service

turbine generator root-valve bonnet fastener was identified as the main cause of

this tragedy. Further investigation revealed that ship’s personnel furnished the

replacement fasteners without properly verifying if the requirements of the

technical manual and drawings were fully satisfied.

3. In 1963 the US.S. Thresher, a U.S. Navy nuclear submarine, was lost at sea

because of flooding in its engine room [18,20]. An investigation identified a

piping failure in one of the salt water systems as the most likely cause for the

disaster. Consequently, many changes were recommended in the submarine

design and maintenance processes.

Past experiences indicate that Post Maintenance Testing (PMT) is quite useful for

increasing the quality of maintenance. Its three main objectives are

a. To ensure that no new deficiencies have been introduced.

b. To ensure that the original deficiency has been eradicated properly.

c. To ensure that the item in question is ready to carry out its stated mission

[21].