Machinery Lubrication magazine published by Noria Corporation
Issue link: http://www.e-digitaleditions.com/i/756816
4 | November - December 2016 | www.machinerylubrication.com AS I SEE IT Figure 2. This expanded-metal guard allows easy inspection of the mechanical coupling. Figure 3. A sight glass can give easy access to oil using a pipette for quick blotter spot and crackle test analysis. Improve the quality of inspection and, by default, you improve the quality of TPM and all the benefits that TPM seeks to achieve. inspections, precision checks, routine lubrication and simple repairs. Autono- mous maintenance breaks down the division of labor that spurs conflict and inefficiencies between the roles of opera- tors and dedicated maintenance workers. The following is an abridged reconstruc- tion of the classic seven-step approach of autonomous maintenance. It underscores the culture of operator engagement, owner- ship and inspection that is foundational to a successful TPM transformation. Initial Cleanliness Restore the machine to an initial opti- mized state of cleanliness, performance, reliability and operating conditions. Below are a few examples that encompass the broad concept of cleanliness: • Leakage • Loosened bolts and connections • Inadequate lubrication • Non-apparent cracks • Lubricant contamination ingression • Defective parts • Exterior dust, moisture, grime and sludge • Interior deposits, sludge and varnish • Contaminated electrical connections • Defective or uncalibrated sensors, transducers and instruments • Need for precision alignment and dynamic balance Standardize the Optimum State Develop and document standards that define the optimized state of cleanliness, lubrication, performance and operating conditions. The optimum state should reflect machine criticality and known failure modes. These standards must be measur- able or verifiable. Individually and collectively, these standards are referred to as the optimum reference state (ORS). Verify Optimum State Compliance Develop inspection protocols, assess- ments and condition monitoring procedures that enable near real-time awareness of the machine's current and transitory state of cleanliness, lubrication, performance and operating conditions. These verify that the machine's cleanliness, lubrication, performance and operating conditions comply with the standardized optimum reference state. Restore and Remediate Establish a regimen of frequently performing these inspections, assessments and condition monitoring practices. Quickly restore all non-compliant condi- tions and operating states to within the ORS according to the documented stan- dards. For example, these include refreshing lubrication levels, locating and stopping leaks, tightening loose bolts, performing mechanical adjustments and making tension measurements. Revise Standards The last step for successful autonomous maintenance is to revise standards and establish a process of continuous improve- ment (kaizen). This includes improving machine maintainability and the ease of maintenance and operation. TPM Produces Real Benefits When well-implemented, TPM usually yields solid, tangible benefits to the organization. These include increased productivity, reduced manufacturing costs, fewer production losses, better product quality and improved safety. There are also less-tangible benefits such as a higher confi- dence level among workers, a clean and attractive work environment, a positive attitude among workers and an overall improved business culture. Inspection 2.0: The Eyes and Ears of TPM Your TPM program is no better than the inspection program on which it depends. It must go way beyond inspecting for faults, cleanliness, orderliness, etc. Inspection 2.0 takes this much further. When inspection improves (earlier detection, better detec- tion and more frequent detection), so too will TPM and the cascading benefits that result. TPM is powerless without a vigilant and probing inspection program. Let's connect the dots and look at how inspection is deeply imbedded in each of the TPM pillars: Autonomous maintenance means auton- omous inspection. Operators rigorously and intensely inspect to verify that the