Maintenance plan

1. MAINTENANCE
PLAN
PAKISTAN TOBACCO COMPANY

2. WHAT IS MAINTENANCE
■ Maintenance is a profession committed to keep
the Industry running in the best possible shape,
making equipment reliable, productive and secure
to use.

3. MAINTENANCE
PLAN
■ PREVENTIVE MAINTENANCE
■ PLANNED CORRECTIVE
MAINTENANCE
■ BREAKDOWN MAINTENANCE

4. IMPLEMENTATION OF PLAN
PREVENTIVE MAINTENANCE (weekly)
PLANNED CORRECTIVE MAINTENANCE
(daily)
BREAKDOWN MAINTENANCE (depends)

5. PREVENTIVE MAINTENANCE (Cont
…)
■ On weekly, monthly and yearly basis
■ Maintenance meeting on regard of
feedback from operator/cell.
■ Successfully handing over the
equipment to the operator.
■ Reduce MTTR and MTBF.

6. CONT …..
■ Elimination of every kind of losses,
for example failure and defect losses
■ Calculation of overall efficiency,
productivity and production/energy
resources and setting targets
■ Bringing equipment and production
up to their optimum state
■ Overall inspection
■ Educate operators
■ Operators maintain their own
equipment
■ Standardization
■ Inventory maintenance

7. Predictive Maintenance
■ Education and Training• Improvement of maintenance
sections to prevent occurrence
of losses
• Daily measures
• Periodic maintenance
• Predictive maintenance
• Service Life extension
improvement
• Spare parts Management
• Failure analysis and
recurrence prevention
• Lubrication management
• Basic maintenance
Process
• Keying
• Bearing maintenance
• Transmission parts
maintenance
• Leak Prevention
• Hydraulic and pneumatic
equipment Maintenance

10. Types of Failure
• Loss-of-failure type
Equipment stops operation
suddenly.
• Functional deterioration type
Equipment is operating but
causes process defect and
other losses.

11. Basic Policy of Failure
■ Equipment failures are caused by human beings
■ Equipment failure can be reduced to zero by changing
the way of thinking and acting of human beings
■ Changing the way of thinking from “Equipment may
fail” to “equipment shall not fail” and “failure can be
reduced to zero”

12. Classification of latent defects
Physically
Latent
defects
• Physically invisible defect
• Found only after equipment is disassembled
• Defects invisible due to inadequate mounting position
• Defects concealed under dust and dirt
Mental latent
defects
• Defects that are undetected and neglected due to lack of
consciousness and skills of maintenance persons and
operators
• People are unconcerned about defects
• People cannot detect defects
• People ignore defects, considering that there is no problem
Latent Defects Dust. dirt, distortion, vibration, noise, abnormal temperature,
leakage, wear, adhesion of raw materials

13. ATTACHMENT
S

14. THE
END