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CHAPTER 1
INTRODUCTION
1.1 Background
Most industrial production systems are subject to deterioration with usage and age. Such system deterioration may lead to higher production costs and lower product quality and
the increased possibility of breakdown Wang and Hwang, 2004. Therefore, a well- planned maintenance management program is important to reduce costly breakdowns
Dohi et al., 2001. In some cases, system failure leads to uncountable costs, for example, the failure of an airplane engine during flight may bring property damage and loss of life.
Therefore, extensive maintenance is necessary to improve the system availability Murthy and Hwang, 1996.
Total Productive Maintenance TPM is a proactive and cost-effective approach to equipment maintenance which is widely adopted in Japanese industries with successful
results Nakajima, 1988. The successful implementation of TPM depends on a number of factors, such as a culture of mutual trust, operators agreeable to providing basic care to
their machines, and maintenance personnel trained in management and people skills Albert and Chan, 2000.
Tsang and Chan 2000 stated that TPM involves a restructuring of work relating to equipment maintenance. Being relieved of such routine tasks, the expertise in the
maintenance unit can now be deployed to focus on more specialized activities such as major repairs, overhauls, tracking and improvement of equipment performance, and
replacement or acquisition of physical assets. Instead of having to continuously fire-fight and attend to numerous minor chores, it can now devote its resources to address strategic
issues such as formulation of maintenance strategies, establishment of maintenance
2 management information systems, tracking and introduction of new maintenance
technologies, training and development of production and maintenance workers.
Total employee involvements, autonomous maintenance, small group activities to improve equipment reliability, maintainability and productivity, and continuous
improvement, or kaizen are the principles embraced by TPM Tsang and Chan, 2000. One of the main arms of TPM is Autonomous Maintenance AM, called as Jitshu Hozen
JH in Japanese. The success of TPM, to a large extent, depends upon the success of AM.
Grinding machine is extensively used in the Machine Shop Laboratory, University Teknikal Malaysia Melaka UTeM to perform the task given especially in
manufacturing practice subject. The machine is exposed to the breakdown as it is not well maintained. Maintenance and machine could not be separate to each other. Machine
needs maintenance like human needs water. Daily maintenance, although it is simple but still could improve the effectiveness and expand the life time of the machine. This project
will provide an organized methodology to perform AM on the grinding machine.
1.2 Objectives
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