A developed autonomous preventive maintenance programme using RCA and FMEA

作者：Chen Chee Cheng^*

来源：International Journal of Production Research, 2013, 51(18): 5404-5412.

DOI：10.1080/00207543.2013.775521

• failure modes and effects analysis
• root-cause analysis
• total productive maintenance
• autonomous preventive maintenance

Total productive maintenance (TPM) was developed in Japan in 1971 and has since been phased into many manufacturing firms to promote productivity and competitiveness. Autonomous preventive maintenance (APM) systems are very special. The fundamental pillar of TPM includes a series of important systematical first-line direct labour activities. The technical cost, human resources and management issues are all considered. Failure modes and effects analysis (FMEA) and root-cause analysis (RCA) are the most popular failure analytical methods, widely adopted over different industries. They are often used to examine the potential problems in the design and manufacturing phase, discovering possible failure causes before product design and manufacturing finalisation. This study integrates the RCA and FMEA techniques to establish an APM system that meets a company's goal of reducing manufacturing costs and promoting employee and equipment productivity. The major contribution of this study is constructing potential equipment failure modes and their risk priority number through RCA and FMEA integration transformed into a selection of items and their APM maintenance frequencies. A strategy for deploying employee technical capability upgrade through effective training is developed. This study uses the S Company - a key manufacturer of semiconductor material - as a case study to verify the model's applicability and suitability.

• 出版日期2013-9-1