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Total productive Maintenance

Autonomous Maintenance

- Step 1

Introduction – Autonomous Maintenance

Autonomous according to the dictionary means ‘independent’, ‘self-sufficient’ or ‘self-governing’

AM is the foundation stone of TPM

• Activities by Operators to create & maintain base

conditions for optimal operation.

• Without operators who can look after their own machines,

losses and break-downs cannot be reduced.

• It is a way to “secure” improvements.

“I am in charge of my machine”

Objective

• Operators become equipment experts

• Problems that stop or slow the machine can be

eliminated by changing the attitude of the people –

Managers, Operators & Technicians In other words

• Zero Defect & Zero Breakdowns can be attained

When:

• equipment works better, people work better

people work better, factory works better

• factory works better, people are happier

7 STEP Implementation

1. Initial Cleaning

2. Counter measures against sources of dirt & difficult

points

3. Develop tentative standards of cleaning,

inspection & lubrication

4. General Inspection

5. Autonomous inspection

6. Standardization

7. Autonomous

Management Stage-3

Standardize maintenance

activities & implement

Autonomous Control

Stage-2

Assessment of the wear on

equipment & Develop activities

to prevent it

Stage-1

Establish Basic Conditions

of the Equipment & Maintain

those conditions

Steps Levels

0. Preparation Get people motivated

Example of Implementation

Issues that Impact OEE

Low operative

efficiency

High # of damages

Deficient

communicacition

High Nº of accidents

Lack of interest of

the operators

Lack of skills

LOSSES DUE TO SETUP

LOSSES DUE TO DEFECT

LOSSES DUE TO RAW MATERIAL

GHEE, THE MARKERS ARE NOT

GETTING BETTER

LACK OF

INTEREST

DIFFICULTY TO MAKE OUT

LACK OF

SKILL

“I OPERATE, YOU REPAIR”

OPERATOR

MAINTENANCE

STAFF

“BE GREATFULL THAT I FIXED YOUR MACHINE”

Selfish attitude

Negative attitude

=

+

NON PRODUCTIVE MAINTENANCE

Issues of Prod & Maint.

TPM View

Operators

Baby Parents Physicians

Machines Maintenance

Operators Should Be Able To

• Understand how the equipment works & identify the causes

of abnormality

• Identify & correct equipment abnormalities

• Understand the relationship between equipment condition &

quality of the product; i.e. foresee quality issues & recognize

the cause.

• Carry our repairs

• Take charge of making improvements; on their own &

through working with other departments

Autonomous Maintenance – Step 1

Step 1 - Initial Cleaning &

Inspection

• Cleaning and Inspection is conducted on the equipment to exposed equipment

abnormalities

• Inspection Means finding problems

• Dust, stains, oils and grease has to be removed

• When cleaning oil leakage, loose wires, unfastened nuts and bolts and worn out

parts must be taken care

• Initial cleaning is not intended to be an overhaul or turn around of the equipment or

process area

• The focus is to increase understanding of the equipment through the cleaning

process

Step 1 – Cleaning & Inspection

A) Meaning of cleaning - Simply stated, removing dust, oil,

stains, cut powder, sludge and other foreign objects from the equipment area.

- Through such activities potential equipment defects are highlighted.

B) Cleaning is inspection

- Confirm safety of cleaning in advance

- Operators should personally engage in cleaning their own work

- Open previously unseen covers or lids

- Disassemble components if necessary with trained maintenance personnel if required.

Step 1 – Initial Cleaning

Step 1 – Hazards of Insufficient Cleaning

Typical hazards that occur from insufficient cleaning include; 1. Causes of failure - Stains and foreign items in revolving units, sliding units, air and oil pressure

systems. Electrical control systems and sensors can also be affected resulting in reduced accuracy, erroneous operation and failures due to resultant wear, clogging, resistance and bad power application.

2. Cause of quality defects 3. Cause of deterioration 4. Cause of speed loss Stains enhance abrasion and sliding resistances, which in turn engender speed losses.

Step 1 – Hard To……. List

Make lists of

Areas/Parts Hard to clean Hard to Lubricate Hard to tighten Hard to adjust Hard to inspect

Record the cleaning time Carry out an audit on step 1 Meeting after daily activities Refer to old history records

Step 1 – Tagging of Hard To…. Areas

Entries in the Hard to list of defects should be tagged on the equipment

• White Tags: Rectified by operator through JH

• Red Tag : Rectified by specialist due to nature of malfunction. White tags would typically include; - Loosening of fitted bolts of limit switches, proximity switched - Replacement of worn screws - Dislocation and twisting of wires - Replacement of damaged V-belts

Step 1 Continued

When exposing defects, it is important to learn how to find these defects and malfunctions. Operators should receive advanced guidance from maintenance on ideal conditions and these should be visualised. Use the five senses to identify abnormal conditions.

Step 1 Continued

Step 1 Continued

Step 1 Continued

Step 1 – Abnormality classification

1. Minor Flaws 2. Unfulfilled basic conditions 3. Inaccessible places 4. Contamination sources 5. Quality defect sources 6. Unnecessary and non urgent items 7. Unsafe places

Refer to JH manual page 72-90

Step 1 – Abnormality classification

Step 1 – Develop Cleaning Maps

Develop drawings or use pre-existing equipment drawings to identify areas to clean that operators can use when doing their daily routine tasks of cleaning is inspecting.

Refer to page 92 and 93 of the JH Manual

Step 1 – Develop Cleaning Maps

Refer to page 92 and 93 of the JH Manual

Summary

Step 1

Autonomous Maintenance

• Operator takes ownership of his/her equipment at all times

• Establish basic conditions of equipment

• Operators become equipment experts