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
The aims of this project are to: 1.
Perform an AM programme on the grinding machine Model: BO 300 A. 2.
Identify and analyze the abnormalities on the grinding machine Model: BO 300 A and the remedies.
1.3 Scope
The scope of this project is only focus on the development of AM programme. The grinding machine Model: BO 300 A which is used in Machine Shop Laboratory of FKP
in UTeM is selected for the project. This project is only focused on the first three steps of AM; initial cleaning, counter measure at the source of the problem, and cleaning and
lubrication standard refer clause 2.6. The data is gathered from primary and secondary
3 data sources. The project is started from December 2007 until April 2008. The result of
this project may not applicable to other types of grinding machines or other machines.
1.4 Importance of Project
The importances of the project are to: 1.
Promote the clean, neat and friendly workplace in FKP Machine Shop Laboratory.
2. Reduce the accident occurs in the FKP Machine Shop Laboratory.
3. Establish an orderly shop floor where any departure from normal conditions
can be identified immediately. 4.
Extends the machines life and improves availability and effectiveness. 5.
Foster the development of knowledgeable students since most of the routine
maintenance tasks are carried out by themselves. 6.
As a reference for academic studies related to AM.
1.5 Outline of Report
The organization of this report is as follows:
Chapter 1 is the introduction of this project, describes the background and problem statement of the project. The objectives, scope, importance of the project and the project
outlines are also presented in this chapter.
Chapter 2 is the literature review about maintenance, describes the definition, concept and evolution of maintenance concept and Total Productive Maintenance. Besides, the
importance of maintenance, characteristic of 8 types of maintenance and TPM are discussed. It is also includes 8 pillars of TPM, OEE, 7 steps in developing autonomous
maintenance, and Fuguai.
4 Chapter 3 is the literature review about grinding machine Model: BO 300A, discusses
about types of grinding machines, grinding wheels and cutting fluid. Besides, this chapter also explain about grinding machine Model: BO 300 A operation, safety and the
machine troubleshooting.
Chapter 4 is the methodology, presents the appropriate methodology of this project. This chapter includes the project process planning, flowchart, Gantt chart, data gathering
method and analytical which is includes Fuguai analysis.
Chapter 5 is the analysis and discussion, presents findings of the project. This chapter also discussed the autonomous steps that were carried out and shows the results obtained.
Chapter 6 is the conclusion, summarizing the project work that has been done. This chapter gives recommendation and proposes future work to improve the maintenance in
FKP Machine Shop Laboratory in UTeM.
5
CHAPTER 2
MAINTENANCE
Chapter 2 presents the literature review regarding the definition, concept and evolution of maintenance and Total Productive Maintenance. Besides,
characteristics of maintenance with description of types and six big loses are discussed. It is also includes the literature
review regarding TPM Pillars, Overall Equipment Effectiveness, autonomous maintenance, and fuguai.
2.1 Introduction to Maintenance
