Equipment Maintenance: Step 1 2 3

PM_46_F7 Rev. No.
: 00 / Jun 2013 , ACT / TRG / 053
Equipment Maintenance Step 123
ACMA Centre for Technology
Since 1989
Equipment Maintenance : Step 1 2 3

Office No. C, 10th Floor, Godrej Eternia,
Old Mumbai Pune Highway, Wakdewadi , Shivaji Nagar Pune 411005, India
Email: act@acma.in , Website: www.acma-act.in
Division of ACMA
Email: act@acma.in Website: www.acma-act.in
PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053
Property Rights :
Intended Audience
This material is a part of the ACT Cluster Approach for Sustainable Training with the purpose of training the Cluster Companies ( who have
joined ACT Cluster Program ) / ACT Training Programs .
Intended use
This Training Material is a property of ACT ( ACMA Centre For Technology ) and to be used for ACT Cluster Programs run by ACT or
any other program run by ACT
Disclaimer
This Training material should be used during ACT Cluster Programs or by the companies after cluster programs ( Companies = Who
were part of ACT Cluster Program ) . Employees of ACT can use / distribute this training material till they are Employee of ACT /
working with ACT .
June 2013
Pune .
Division of ACMA
Equipment
Maintenance :
Step 1 2 3
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My
Machine
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Division of ACMA
OR
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Why there is a
Difference in two
words MY ?
Answer
= Refer last slide
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MY
Machine
My machine is a
part of Total
Employee Involvement and it is
matter of SELF-PRIDE*
*Self Pride = Owning the responsibility
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In productivity improvement ,
focus is frequently on operator.

It is true that operators work
deserve some attention , but when

we clearly define operators work
, FOCUS SHOULD BE ON
MACHINES
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Machines are assets of

company like People , THEN
WHY NOT TO IMPROVE THE
MACHINE CONDITIONS
And goal should be
BE PERFECT
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BE PERFECT
Means..
ZERO INCIDENCES of any type of
unexpected failures *
* Unexpected Failure = A reason which does not allow to run the machine.
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Goal BE PERFECT
Exercise for the participants :List down possible unexpected machine failures
in your company , zone , cell / line
1.
5.
2.
6.
3.
7.
4.
8.
* Unexpected Failure = a reason which does not allow to run the machines.
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Goal BE PERFECT
Now understand at this point

Various unexpected failures
=
Losses in various forms
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Goal BE PERFECT
Let us make it further EASY
Unexpected FAILURES = LOSSES
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Goal BE PERFECT
So what is our answer to these failures ?
A] Can we eliminate the failures ?

B] Can we reduce the failures ?
C] Can we postpone the failures ?
YES , then FAQ * = HOW ?
* FAQ = Frequently Asked Question
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Failures
Let us understand the effect of the failures
Available time = Company start to close
Non -productive
actions
Gross machine time

Downtime /
Breakdowns
Net machine time

Useful time
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Non Quality
16
Failures
Let us understand the effect of the failures
Available time = Company start to close
Useful time
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Non Quality
Breakdowns
Non -productive actions
17
So Let us make improvements
through
My Machine
( STEP 1 ,2 ,3 )
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Implementation methodology :1. Select one machine from critical machines

2. Select the team for My Machine ( Team must consist of all
Head of Departments , Production Head, Engineers from
Mechanical , Electrical , Electronics areas. Production head will
be the team leader.)

3. Communicate to all employees for launch of this My
Machine program.
4. Follow C L I T concept
TRAIN THIS TEAM by using this training material FIRST .
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Implementation methodology :- Contd

5. Decide daily improvement working time by this team
6. Track progress of the improvements ( Dont forget to track
attendance of team members. Assign responsibilities for data
updating )
7. Implement Step 1 , 2 and 3
7. Achieve Zero Unexpected failures

8. Hand over this machine to operator for maintaining after
making machine completely Visual * with C L I T Standards
* Visual = Explained at the later part of presentation
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Things to be made available before Implementation

1. Set of Various tools ( Spanners , Allen keys )
2. 200 Abnormality tags * with tying threads , rubber bands
( 2 Colors 100 each ) and two small boxes
3. Cleaning items ( Cotton rags , cloths , wire / soft Brushes , used
/ new tooth brushes ) .
4. Set of hand gloves
5. A copy of Machine manual
6. Digital camera ( Assign responsibility )
7. Set of simple printed / Xeroxed formats**
* Abnormality tag = refer next slide
** Formats = Available at the end
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ACT
ACMA
12 mm
ACT
ACMA
Abnormality TAG
Abnormality TAG
RED
WHITE
Small Abnormality found

here
Machine :____________ M/C
No.____
Small Abnormality found

here
Machine :____________ M/C
No.____
Sub-assembly:___________________
Sub-assembly:___________________
110 mm
Date :-_____/____/ 20__

Description of Abnormality
Found by :-____________________
Remove this sheet after attaching to

Abnormality place and use it as a ref.. copy
Date :-_____/____/ 20__

Description of Abnormality
Found by :-____________________
Remove this sheet after attaching to

Abnormality place and use it as a ref.. copy
80 mm
Print in duplicate with carbon paper between

two and then stapler pin at top
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Step 1 , 2 and 3
Step 1 ,2 and 3 are the foundation steps in machine improvement
STEP 1 =
STEP 2
THOROUGH CLEANING of all parts of machine
= Make machine for
Easy C L I T
STEP 3 = Formulation of LUBRICATION and

CLEANING STANDARDS
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Step 1
Step 1
```````THOROUGH
CLEANING```````````
of all parts of machine
Action
Purpose
Thorough cleaning
( All Sides of the
machine)
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* Cleaning is Checking
* Identify defects
How
My machine
compaign
Result
Example
No oil Leak
No air leak
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Step 1
Step 1
```````THOROUGH
CLEANING```````````
of all parts of machine
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Step 1
Cleaning
What is Cleaning ?
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Step 1
Cleaning
Machine is like a Baby
, like baby it does not
remain clean itself
. External agency
( Mother ) should
maintain the baby.
Note :- BABY grows over a time period , machine does not
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Step 1
Cleaning
Cleaning does not mean
Bathing without head wash
( Cleaning some part of machine )
A CROW BATH
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Step 1
Cleaning
How we Prepare for a bath ?
First we remove maximum possible clothes
( Removing maximum guards from m/c)
. Then we ensure cleaning media that is Water
( Kerosene , Industrial cleaner for machine )
. We also ensure availability of Shampoo , soap which is for
different parts of the body

( for machines ,use different cleaning agent for different parts )
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Step 1
Cleaning
How we bath ?
.. With the help of cleaning media , we first remove all

possible dust from entire body ( Remove dust from entire
parts of machine)
. Then we scrub oily , dirty areas with scrubber

. We immediately wash this scrubbed area and see the
improvement ( No test facility available other than eyes and
hands )
We also give major attention for the hidden areas Like
?????
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Step 1
Cleaning
How we bath ?
Hidden areas Means . Areas which are normally have less

space between two parts
Example :-Areas between two fingers of feet

- In machines , areas between slides , slots
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Step 1
Cleaning
How we bath ?
Now at this point can we convert bathing
sequence in a flow chart as follow :( Refer Next slide )
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Step 1
Cleaning
How we bath ?... bathing sequence
Clean
Next Day
CHECK
Correct
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CHECK
33

Step 1
Cleaning
Now , Can we say..
CLEANING
means
CHECKING
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Step 1
Cleaning
Clean each and every part of the machine
- Top of the machine
- Below machine
- Inside guards ( Remove all guards )
- Motor fans ( Remove fan guard)
- Inside belt guards
- Electrical panel should be cleaned

by Electrical persons only
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AND
Checking
Step 1
While cleaning , check Abnormalities and attach relevant

tags ( White / Red )
You can look for following Abnormalities

( These are sample Abnormalities , you will get much more
Abnormalities in your machine )
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Checking
check following while cleaning

the machine
Step 1
Loose components
Rusted parts
Loose wires
Broken parts
Cracked parts
Air leak
Oil leak
Coolant leak
Dirt and dust in the parts
Oil spillage on the floor
Swarf around the machine
Unwanted materials
Missing parts
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Step 1
CHECKING for Abnormalities
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Step 1
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Step 1

Missing
Missing
Missing
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Missing
40
Now implement Step 1
Step 1
1.1 Go to your machine and switch off the main power supply.
( Remove Fuses )
1.2 Start cleaning the machine.
1.3 Find Abnormalities in the machine and its accessories.
1.4 Fill up the details in the RED or white Abnormality tag based
on the nature of the Abnormality.
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Now implement Step 1 Contd.
Step 1
What to be filled in the Abnormality tag?
1) Machine Number
2)Date
3) Sub-Assembly of the machine or location where Abnormality
noticed
eg. Cylinder, Hydraulic tank, Lubrication tank, Motor, etc.
4)Found by (Employee name / number)
5) Description of Abnormality (Use correct words )
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Now implement Step 1 Contd.
Step 1
1.5 Take corrective action on White tag

( Write details of action taken on backside of the tag )
1.6 Remove White tag

1.7 Keep removed tags in the box
1.8 RED tags to be removed ( after correction ) by experts (
Maintenance , Engineering etc. )

1.9 Before leaving machine , ensure that NO WASTE , Dirt is
lying near the machine and Machine is running normally
1.10 Now , enter the details of Abnormality tags in the

Abnormality list format ( required for further analysis )
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Step 1 , 2 and 3
STEP 1 =
STEP 2
= Make machine for
Easy C L I T

CLEANING STANDARDS
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Step 1 , 2 and 3
Step 2
STEP 1 =
STEP 2
= Make machine for
Easy C L I T

CLEANING STANDARDS
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Step 2
STEP 2
Make machine for
Easy C L I T
C= Clean , L= Lubricate
I = Inspect , T= Tighten
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STEP 2
= Make machine for
Action
Easy C L I T
Purpose
1) Convert difficult to clean

to easy to clean
2) Convert difficult to see
to easy to see
Step 2
Result
* Clean & tidy machine

* No forced detorioration
* To avoid machine failure
* Identify abnormality &
correct on continous basis
3) Convert difficult to lubricate To facililate daily/periodic * To avoid machine failure
to easy to lubricate
lubricatiion
due to inadequate / no
lubrication
* To indentify frequency of
oil change,leakages on
continous basis
4) Implement machine
Achieve wet to dry
* Preventing forced
modification kaizen
(Localized cover,preventing detoriaorationof machine parts
contomination at source
* Cleaning time reduction
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To Facililate daily
cleaning by operator
To Facililate inspection
by operator
47

Step 2
Examples
Difficult to Clean
to
Easy to Clean
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Easy to clean
Before
Idea :Slope bed

After
Difficult to remove the

burr from the machine
bed
Fixture and drill head

mounted in the hollow
frame bed with burr
collection tray
Solid machine bed
Hollow bed
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Step 2
Benefits
1. Reduced cleaning
time from 5 minutes to
1 minute
49
Easy to Clean / Lubricate
Idea : Shifting
Before
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Step 2
After
50

Step 2
Examples
Difficult to Inspect
to
Easy to Inspect
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Easy to Inspect
Before
Idea :Air flow indicator

After
Difficult to inspect
exhaust fan working
Step 2
Benefits
Provided air flow indicator 1. Reduced inspection

with plastic ball
time from 2 minutes to
arrangement
1 minute
2. Eliminated unsafe
condition
Scope for Horizontal

Deployment :
Exhaust fan
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All CNC machines with

Air flow indicator air cooler
52

Step 2
Make things easy to see
Before
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After
53
Easy to inspect
Before
Idea :Provide mirror

After
Difficult to check leak at Provided mirror to ease

the back during leak test leak check at the back
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Step 2
Benefits
1. Customer complaint due

to error in testing eliminated
54

Step 2
Easy to inspect
Idea :Provide VCS
Oil condition monitoring board
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Step 2
Make things
easy to see
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Step 2
Examples
Difficult to Lubricate
to
Easy to Lubricate
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Easy to lubricate
Before
Idea :Oil funnel

After
Difficult to fill oil in the

lub tank due to smaller
mouth
Step 2
Benefits
Provided oil filling funnel 1. Eliminate oil

with big mouth
spillage's.
2. Wet to dry.
3. Reduced lubrication
time from 2 minute to
1/2 minute.
Scope for Horizontal

Deployment :
Small oil fill mouth

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Oil filling funnel
All machines with lub tank
58
Easy to lubricate
Before
Idea : Knurled plug

After
Difficult to fill oil in the

speed gear box
Step 2
Benefits
Provided knurled plug for 1. No tools required to

oil filling port
fill
oil
2. Reduced lubrication
time
from 4 minutes to 1
minute
MS plug - requires
spanner to remove
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Knurled plug
59

Step 2
Easy to lubricate
Before
After
Lub tank
brought at
front side
JH step 2
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Step 2
Examples
Prevent contamination
at source to achieve
Wet to Dry
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Wet to dry
Before
Idea : Localized Cover

After
Mitsuiseiki HMC
Step 2
Benefits
1. No spillage of burr and

on the floor
Burr splash during

machining on the floor
Provided localized cover

to avoid burr splash
during machining
2. Reduce cleaning time

from 45 minutes to 10
minutes
3. Better house keeping
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Wet to dry
Before
Idea : Localized Cover

After
Systec Drill & Tap SPM

Coolant splash during
machining on the floor
Step 2
Benefits
1. No spillage of burr and

coolant on the floor
Provided localized cover

to avoid coolant splash
during machining
2. Reduce cleaning time

from 15 minutes to 2
minutes
3. Better house keeping
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Step 2
Wet to dry
Idea : Coolant jet cleaning to avoid burr flying
Before - Air Cleaning
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After - Coolant jet cleaning
64

Step 2
Wet to dry
Idea : Cover to avoid burr flying
Before - No closed enclosure
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After - Provide closed enclosure
65
Examples
Step 3
Step 3
Handing over the M/C to

Operator for executing
daily checks ( C,L,I,A )
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Visual Controls
Activity
Symbol
Step 3
Tools
Clean
Lub
Inspection
NO
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Step 3
How to prepare Cleaning , Lubrication and

Inspection Standard ?
1. Draw a Schematic diagram of Various CLI points of the
Machine.
2. Mark various locations for C L I on diagram.
3. Start using this standard.
4. Design simple daily C L I monitoring Checklist.
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Step 3
Color code for frequency

Daily Weekly Fortnightly Monthly
Clean
Lub
Inspect
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Formats
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Abnormality List
Machine No.
S. Date of
N. detection
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Found
by
Abnormality
Why it has
happened
What is to be
done to correct
it ( Action )
Resp
TAG :onsibi
R/W
lity
Target
Date
71
ATTENDANCE
Name / Date 1
S.N.
Time
SHEET
4
for the month ..

9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31
Daily
1
2
3
4
5
6
7
8
9
TOTAL PERSONS
PRESENT
OUT OF
SIGNATURE OF TEAM
LEADER
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Answer for the Word
MY
It is our decision
. Our belief
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Thank You
For more details , Contact

Office No. C, 10th Floor, Godrej Eternia,
Old Mumbai Pune Highway, Wakdewadi , Shivaji Nagar Pune 411005, India
Email: act@acma.in , Website: www.acma-act.in
Division of ACMA
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PM_46_F7 Rev. No.

: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

ACMA Centre for Technology

ACMA Centre for Technology

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

focus is frequently on operator.

deserve some attention , but when

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Machines are assets of

And goal should be

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Now understand at this point

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Unexpected FAILURES = LOSSES

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

A] Can we eliminate the failures ?

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Gross machine time

Net machine time

Email: act@acma.in Website: www.acma-act.in

PM_46_F7 Rev. No.: 00 / Jun 2013 , ACT / TRG / 053

Equipment Maintenance Step 123

Email: act@acma.in Website: www.acma-act.in

Date :-___// 20

Date :-___// 20