Have you ever heard of TPM?
You may have heard that you work in a manufacturing factory.
It’s a story about maintenance, so it’s only for engineers, right?
And there may be some people who think that even in the factory, the clerical work is not concerned.
TPM was popular for a while, but people who think this way are the same not only in clerical work but also in engineering.
Even maintenance personnel are confused by the unusually large number of related technical terms.
So let’s focus on the really important parts.
I feel that if I can use these three terms as a matter of course in terms of industry terms, I will take a step forward as a maintenance person.
I have a feeling that I know this person.
Other abbreviations are OK if you look at them with a casual feeling like “There are such things.”
Preventive maintenance (PM)
There is a concept called PM (preventive maintenance) in maintenance.
PM is a basic concept in modern conservation.
PM stands for predictive maintenance.
Simply put, the idea is to protect it before it breaks . Simple, isn’t it?
It seems that it was terrible when there was no such concept.
Fix it after it breaks. It can’t be helped even if it breaks.
It seems that there were many days of production stoppage compared to the operation of 365 days a year.
PM consists of the following three maintenance methods.
- TBM
- CBM
- BM
In a batch plant, in practice, just knowing these TBM, CBM, and BM will reach the acceptable level as a TPM.
Scheduled maintenance (TBM: Time Based Maintenance)
TBM stands for Scheduled Maintenance.
This is a method in which periodic inspections are determined for each piece of equipment and parts are replaced.
In human terms, annual health checkup.
The only similarity is that you receive it every year regardless of whether you are healthy or unhealthy, and you decide the cycle.
As expected, in the case of humans, it is not possible to replace parts on a regular basis.
Instead of using it until it breaks, let ‘s check the equipment regularly and replace it.
It may seem obvious, but you can’t say that if you have a lot of equipment.
You can claim that you are doing maintenance, but there is a possibility that it will be overmaintenance.
Even if maintenance is not performed this year, there is a possibility that it has not broken down for more than a year, but after four years it may be replaced.
TBM covers 20-30% of equipment in batch chemical plants.
Predictive maintenance (CBM: Condition Based Maintenance)
CBM is predictive maintenance.
Also called state maintenance.
This is a method for diagnosing the condition of equipment and determining the appropriate maintenance timing.
Decisions are made based on periodic records such as operating data, daily inspections, and periodic inspections.
In human terms, take your temperature every day and rest if your temperature is high.
It is a term that is likely to be misunderstood as TBM in the sense of collecting data on a regular basis.
- TBM replaces parts regularly
- CBM periodically collects data and replaces parts according to its condition.
This is the proper use of TBM and CBM.
CBM has the advantage of preventing over-maintenance, but has the disadvantage of requiring more man-hours for data collection.
CBM is limited to especially important . A few to 10 units.
Breakdown Maintenance (BM)
In BM , it is called post-maintenance.
Replace if broken.
In terms of human beings, do you throw away hair and nails when they grow ?
Evening is a little difficult.
In the case of humans, there are almost no cases where we leave it alone until it breaks.
BM is a very important concept in equipment.
This is because in maintenance, it is not possible to cover all facilities with limited forces.
Give up looking at equipment that does not have a big impact even if it breaks down, and deal with it after it breaks down. take the method.
It is an important consideration in the maintenance concept of the factory to determine which equipment is BM.
It is not the idea that BM is for unimportant equipment.
Other terms
I think that the terms TPM, TBM, CBM, and BM are sufficient in practice.
There are other terms, but I will introduce them for reference.
Corrective maintenance (CM)
The idea is to improve the function as much as possible, rather than fixing it when it breaks.
It used to be popular in Japan in the past, but now it is becoming difficult with chemical equipment.
This is because the number of chemical equipment manufacturers that cooperate with us is decreasing sharply.
Maintenance Prevention (MP)
Wouldn’t it be better to call it conservation rather than conservation?
It should not be discussed in terms of conservation.
Productive Maintenance (PM)
Maintenance that minimizes equipment purchase cost + equipment operating cost + equipment repair cost.
In order to take this thought, BM thinking is important.
Is it better to use TBM for 40 years in a 4-year cycle, or is it better to replace 4 times every 10 years on average with BM?
BM tends to be an afterthought because it is not possible to predict how often it will break.
However, there is also a way to make it a facility configuration that can be done with BM as an idea.
An easy-to-understand example is preparation for installation.
MP≠PM
Some people who only vaguely see the word equate MP and PM.
Is it just a typo?
It’s a simple idea.
The two are distinctly different.
- MP stands for Maintenance Prevention
- PM stands for Productive maintenance
PM is conservation itself
You can think of PM as the prototype of TPM , that is, as conservation activity itself.
It is the concept of so-called maintenance work, and the categories such as TBM, CBM, and BM are specific methods of PM.
In that sense, thinking of TPM/PM and TBM/CBM/BM in parallel is misaligned.
It’s horizontal, so it means the same thing, right? It’s funny to think
MP is improved design maintenance
MP is a little out of the way in terms of conservation work.
- Nothing progresses by simply fixing broken equipment.
- Investigate the cause, take countermeasures, and prevent the same equipment trouble from occurring.
This activity is called MP.
In recent maintenance, there are many cases in which parts are replaced on an emergency basis, so improvements are slow to progress.
This is because the manufacturer’s improved design has reached its limit.
The user side is also left to the improvement design of the manufacturer, and they can not take any responsibility themselves.
This relationship exacerbates the problem.
TPM is Total PM
TPM stands for Total Preventive maintenance.
PM is Total version.
Develop PM as a whole. The idea is to think of it as a system and work on it.
Anyone who works in the manufacturing industry knows TPM.
But few people know what the TPM abbreviation means.
Not many people understand that it is part of the PM’s role in conservation.
reference
Related article
lastly
The word TPM is probably more widely known than the word PM.
Equipment maintenance engineers use the terms TBM, CBM, and BM on a daily basis.
If you know the system around here, you will deepen your understanding of conservation.
Please feel free to post your worries, questions, and questions about the design, maintenance, and operation of chemical plants in the comments section. (The comment section is at the bottom of this article.)
*I will read all the comments and answer them seriously.