4-Autonomous Maintenance 06 Sept 2007

I0701 ISSUE 1 4-AM.PPT/1

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TQM International Pvt. Ltd. 52 Community Centre, 2nd Floor, East of Kailash, New Delhi-110 065

Autonomous Maintenance (AM)


Why Autonomous Maintenance? The equipment is filthy & stays

that way only Oil & lubricants leaks are

common and lubricators are empty

Rotating parts & moving surfaces are encrusted with grime & raw material

Wires & hoses are tangled and you can't tell what is connected where

Equipment mechanisms are hidden by big covers & you can't see inside

Materials, parts, tools and supplies are strewn randomly & you can't tell what is essential and what is not

Everyone is utterly convinced that things have to be that way

Workplace suffer with many defects & equipment

breakdown


Autonomous Maintenance


The role of people is to maintain machines

− So that they work properly

− Without breakdowns

− Without defectsThe principle in autonomous maintenance is "I operate & I

Maintain the equipment"My machine

concept

Autonomous Maintenance


Autonomous Maintenance - Background

I Operate, You Maintain Wide gap in mind set of operation & maintenance people

Poor/ no Analytical Approach

Inadequate Training


Develop Process & Equipment competent Operators to enhance productivity We operate We maintain We together WIN, together LOOSE

Establishment of self management at circle levels

To make all operators aware of loss, cost & new techniques

Autonomous Maintenance - AIM


Achievement Indexes

• Variable cost• Fixed cost-Factory Overhead• Labour productivity• Added value productivity• Labour reduction ratio• Savings over previous corresponding period• Number of complaints-Quality & Short supply-• Number of accidents &hours lost.• Better space utilization

Autonomous Maintenance - PILLAR


What is Autonomous Maintenance?

• This part of maintenance is most important and performed by operator themselves.

• The operators take up the ownership of the equipment for the maintenance.

• The principle of “I operate” and “I maintain” is adopted.


Goals of Autonomous Maintenance?The goals of Autonomous maintenance is to keep the

plant operating efficiently so as to meet production targets without any breakdowns. This is achieved by:• Preventive equipment deterioration through daily checks• Restore equipment to ideal state• Establishing basic conditions for upkeep of the equipment• By bringing flexibility in operators to operate and maintain equipments• By focusing on reliability and maintainability


Step-2 Eliminate source of contamination and inaccessible places to reduce time for cleaning, checking and lubricate

Step-3 Establish cleaning, Inspection & lubrication standards to keep equipment in peak optimal conditions and stop deterioration

Step-4 Developing equipment competent operator through training for general inspection

Step-5 Developing process competent operator for general inspection through training

Step-6 Systemize Autonomous Maint. through standardisation

Step-7 Full self management at circle levels

Step-1 Perform Initial Cleaning to eliminate dirt,dust, grime and expose all abnormalities

Steps of Autonomous Maintenance


Basic 7 steps of Autonomous Maintenance

Autonomous Maintenance activities are implemented in steps and are only effective if progressed from one step to next step is strictly controlled.


First step Autonomous Maintenance?Importance of Initial Cleaning: consists of removing all dust, dirt, grime, oil,

grease, other contaminants to equipment for exposing hidden defects.

Breakdown occurs as we do not notice slight problems or abnormal conditions

Slight problems include:−Dirt−Grime−Small amount of wear−Scratches−Play−Looseness−Leaks−Corrosion−Deformation−Vibration−Cracks−Excess heat

Cleaning Inspection Sighting abnormalities


Harmful affects on inadequate cleaningFailure Dirt and foreign matter penetrates rotating parts,

sliding parts, pneumatic and hydraulic systems, electrical control systems, and sensors, etc., causing loss of precision, malfunction, and failure as a result of wear, blockage, frictional resistance, electrical faults, etc.

Quality Defects

Quality defects are caused either directly by contamination of the product with foreign matter or indirectly as a result of equipment malfunction.

Accelerated Deterioration

Accumulated dust and grime make it difficult to find and rectify cracks, excessive play, insufficient lubrication, and other disorders, resulting in accelerated deterioration.

Speed Losses

Dust and dirt increase wear and frictional resistance, causing speed losses such as idling and underperformance.


Key Points for CleaningCleaning is a form of inspection in TPM, so as to expose hidden defects and abnormality in equipment.

Cleaning means• Regular practice as a part of daily work• Removal of layer of grime • Removal of dust & dirt in all attachment and

accessories • Investigation of sources of contamination


Key Points of InspectionCleaning as inspection means detecting abnormalities/ defects in equipment so as to restore into working condition.

This means:• Searching visible defects i.e. looseness vibration, overheating.• Searching worn out gullies, belts, block filters etc.• Searching easy method to lubricate operate and adjusts • Ensuring all meters operate correctly and clearly marked with specific value.• Searching any leakages of product, steam, water, oil, compressed air• Also searching hidden problems such as corrosion,

insulating material and blockages.


What is Daily Checking?Standards and one point lesson should be drawn up for daily checks. Check sheets are meaningful and in true sense daily inspection should be carried accordingly.

Checkpoints for Nuts and BoltsSlight defects Are any nuts or bolts lose?

Are any nuts or bolts missing?Bolt Lengths Do all bolts protrude from nuts by 2-3 thread lengths?Washers Are flat washers used on long holes?

Are tapered washers used on angle bars and channels? Are spring washers used where parts are subject to vibration? Are identical washers used on identical parts?

Attachment of Nuts and Bolts

Are bolts inserted from below, and are nuts visible from the outside?

Are devices such as limit switches secured by at least two bolts? Are wing nuts on the right way around?


What is Daily Checking?Lubrication checkpoints

Lubricant Storage

Are lubricant storage always kept clean, tidy, and well-organized by thorough application of the 5S principles?

Are lubricant containers always capped? Are lubricant types clearly indicated and is proper stock control

practiced?Lubricant Inlets

Are grease nipples, speed reducer lubricant ports, and other lubricant inlets always kept clean?

Are lubricant inlets dust proofed? Are lubricant inlets labeled with the correct type and quality of

lubricant?Oil-level Gauges

Are oil-level gauges and lubricators always kept clean, and are oil levels easy to see?

Is the correct oil level clearly marked? Is equipment free of oil leaks, and are oil pipes and breathers

unobstructed?Automatic Lubricating Devices

Are automatic lubricating devices operating correctly and supplying the right amount of lubricant?

Are any oil or grease pipes blocked, crushed or split?

Lubricant condition

Are rotating parts, sliding parts, and transmissions (e.g. chains) always clean and well-oiled?

Are the surroundings free of contamination by excess lubricant?


What is Daily Checking?Transmission System checkpoints

V-belts and Pulleys

Are any belts cracked, swollen, worn, or contaminated by oil or grease?

Are any bolts twisted or missing? Are any belts stretched or slack? Are multiple belts under uniform tension and all of the same

type? Are top surfaces of belts protruding above the pulley rims? Are

the bottoms of any pulley grooves shiny (indicating a worn belt or pulley)?

Are pulleys correctly aligned?Roller Chains

Are any chains stretched (indicating worn pins or bushings)? Are any sprocket teeth worn, missing, or damaged? Is lubrication between pins and bushings sufficient? Are sprockets correctly aligned?

Shaft, Bearings, and Couplings

Is there any overheating, vibration or abnormal noise due to excessive play or poor lubrication?

Are any keys or set bolts loose or missing? Are any couplings misaligned or wobbly? Are any coupling seals worn? Are any bolts slack?

Gears Are gears properly lubricated with the right amount of lubricant? Are the surroundings clean?

Are any teeth worn, missing, damaged, or jammed? Is there any unusual noise or vibration?


What is Daily Checking?Hydraulic units

Hydraulic Units

Is the correct quantity of fluid in hydraulic reservoirs, and is the correct level indicated?

Is fluid at the correct temperature? Are the maximum and minimum permissible temperatures indicated?

Is fluid cloudy (indicating air entrainment)? Are all fluid inlets and strainers clean? Are any suction filters blocked? Are any fluid reservoir breather filters blocked? Are all fluid pumps operating normally without any unusual noise or vibration? Are hydraulic pressures correct, and are operating ranges clearly displayed?

Heat Exchangers

Is any fluid or water leaking from fluid coolers or pipes? Are temperature differences between fluid and water inlets and outlets

correct? Are any tubes blocked?Hydraulic Equipment

Are there any fluid leaks? Are hydraulic devices properly secured without any makeshift fastenings? Are hydraulic devices operating correctly without speed losses or breathing? Are hydraulic pressures correct, and are all pressure gauges working correctly

(zero points, deflection)?Piping and Wiring

Are all pipes and hoses securely attahced? Are there any fluid leaks? Are any hoses cracked or damaged? Are all valves operating correctly? It is easy to see whether valves are open or

shut? Are any pipes, wires, or valves unnecessary?


What is Daily Checking?Pneumatic checkpoints

FRLs* Are FRLs always kept clean? Is it easy to see inside them? Are they fitted the right way around?

Is there sufficient oil, and are the drains clear? Is the oil drip rate correct (approximately 1 drop for every 10 strokes)? Are FRLs installed no more than 3 m from the pneumatic equipment? Are pressures adjusted to the correct vale and are operating ranges

clearly indicated?Pneumatic Equipment

Is any compressed air leaking from pneumatic cylinders or solenoid valves?

Are all pneumatic cylinders and solenoid valves firmly attached? Are any makeshift fixings in use (wire, adhesive tape, etc.)? Are any pistons dirty, worn, or damaged? Are speed controllers installed the right way around? Is there any abnormal noise or overheating of solenoid valves, and are

any lead wires chafed or trailing?Piping and Wiring

Are there any places in pneumatic pipes or hoses where fluid is liable to collect?

Are all popes and hoses clipped firmly into place? Are there any compressed-air leaks? Are any hoses cracked or damaged? Are all valves operating correctly? Is it easy to see whether valves are

open or closed? Are any pipes, wires, or valves unnecessary?


What is Daily Checking?Electrical checkpoints

Control Panels

• Are the interiors of distribution boards, switchboards, and control panels kept clean, tidy, and well-organized by the application of the 5S principles? Have any extraneous objects or flammable materials been left inside?

• Is the wiring inside control panels in good condition? Are any wires coiled or trailing?• Are all ammeters and voltmeters operating correctly and clearly marked?• Are any instruments or display lamps broken? Are any bulbs faulty?• Are any switches broken? Do all switches work correctly?• Are control panel doors in good condition? Do they open and close easily?• Are there any unused holes? Are control panels waterproof and dustproof?

Electrical equipment

• Are all motors free of overheating, vibration, and unusual noise and smells?• Are all motor cooling fans and fins clean?• Are any attachment bolts loose? Are pedestals free of cracks and other damage?

Sensors • Are all limit switches clean and free of excessive play?• Are the interiors of all limit switches clean? Are any wires trailing? Are all covers in good

condition?• Are any limit switches incorrectly installed?• Are any limit switch dogs worn, deformed, or the wrong shape?• Are all photoelectric switches and proximity switches clean and free of excessive play?• Are any sensors out of position? Are correct positions clearly indicated?• Are all lead wires un-safed, and is insulation intact at entry points?

Switches • Are all manual switches clean, undamaged, and free of excessive play?• Are all switches installed in the correct position?• Are emergency stop switches installed in appropriate locations, and are they working

correctly?Piping and Wiring

• Are any pipes, wires, or power leads loose or unsecured?• Are any ground wires damaged or disconnected?• Are any pipes corroded or damaged? Are there any bare wires or wires with damaged

insulation?• Are any wires coiled on the floor or dangling overhead?


What is Daily Checking?Checkpoints for General-Purpose equipmentPumps

Are pumps and their stands free of unusual noise, vibration, and play? Are pedestal bolts tight, corrosion-free, and undamaged? Are stands and pedestals free of corrosion, cracking, and other damage? Is any liquid leaking or spraying from gland packings? Is any liquid leaking or spraying from pipes or valves? Are any pipes or valves blocked? Are all pressure gauges, vacuum gauges, flow meters, thermometers, and other

measuring instruments working properly and marked with the correct operating ranges?

Are starting current and operating current values correct? Are these clearly indicated?

Are all valves operating correctly? Is it easy to see whether valves are open or closed?

Fans Are fans and their stands free of unusual noise, vibration, and play? Are all pedestal bolts tight, corrosion-free, and other damage? Are all stands and pedestals free of corrosion, cracking, and other damage? Are any gland packings leaking air or gas? Are any ducts or dampers leaking air or gas? Are any ducts blocked or clogged? Are all pressure gauges, vacuum gauges, flow meters, thermometers, and other

measuring instruments working properly and marked with the correct operating ranges?

Are starting current and operating current values correct? Are these clearly indicated?

Are all dampers operating correctly? Is easy to see whether dampers are opened or closed?


The idea is to restore the equipment to basic conditions for normal operation by:

− Cleaning & inspecting: Keeping dirt & grime off the equipment & expo-sing defects & discovering problems

− Lubrication: To prevent wear & overheating of sliding & rotating parts by providing proper lubrication

− Tightening: Basic machine compo- nents like nuts & bolts. Missing or loose bolts leading to excessive vibrations & machine breakdowns

Basics of cleaning & inspection

Summary of CLIT


Steps in Autonomous Maintenance1. Preparation of employees.

2. Initial cleanup of machines. 3. Take counter measures 4. Fix tentative JH standards 5. General inspection 6. Autonomous inspection 7. Standardization and 8. Autonomous management.


Train the EmployeesEducate the employees about TPM, Its advantages, JH (Jishu Hozen) advantages and Steps in JH. Educate the employees about abnormalities in equipments.


Initial cleanup of machines • Supervisor and technician should discuss and set a date for implementing step• Arrange all items needed for cleaning • On the arranged date, employees should clean the equipment completely with the help of maintenance department. • Dust, stains, oils and grease has to be removed. • Following are the things that has to be taken care while cleaning. They are Oil leakage, loose wires, unfastened nuts and bolts and worn out parts.

Contd…


• After clean up problems are categorized and

suitably tagged. White tags is place where problems can be solved by operators. Pink tag is placed where the aid of maintenance department is needed. • Contents of tag is transferred to a register. • Make note of area which were inaccessible. • Finally close the open parts of the machine and run the machine.

Initial cleanup of machines


Counter Measures• Inaccessible regions had to be reached easily. E.g. If there are many screw to open a fly wheel door, hinge door can be used. Instead of opening a door for inspecting the machine, acrylic sheets can be used. • To prevent work out of machine parts necessary action must be taken. • Machine parts should be modified to prevent

accumulation of dirt and dust.


Tentative Standard• JH schedule has to be made and followed strictly.

• Schedule should be made regarding cleaning, inspection and lubrication and it also should include details like when, what and how.


General Inspection • The employees are trained in disciplines like

Pneumatics, electrical, hydraulics, lubricant and coolant, drives, bolts, nuts and Safety. • This is necessary to improve the technical skills of employees and to use inspection manuals correctly. • After acquiring this new knowledge the employees should share this with others. • By acquiring this new technical knowledge, the operators are now well aware of machine parts.


Be able to spot abnormalities

Carry out daily checks reliably & judge correctly when things are abnormal

Understand the structure & function (i.e. operation) of the equipment

Use the five senses to catch abnormalities while the equipment is running Repair & restore

Improve machine operation to make it easier Correct problems & restore equipment

observing & practicing simple repairs with maintenance people) Set criteria

to draw up, apply & teach inspection criteria Keep equipment running

by knowing how to operate equipment properly Track down causes

Abnormality detection and corrective action


Autonomous Inspection• New methods of cleaning and lubricating are used. • Each employee prepares his own autonomous chart/ schedule in consultation with supervisor. • Parts which have never given any problem or part which don't need any inspection are removed from list permanently based on experience. • Including good quality machine parts. This avoid defects due to poor JH. • Inspection that is made in preventive maintenance is

included in JH. • The frequency of cleanup and inspection is reduced based on experience.


Classification

No. Place or Section

Standards Method Tools & Handling

Time (In Secs)

Cycle Person in charge

During Operation

During Stoppage

Cleaning 1 Cleaning of pump body

Free from dirt

Wiping 300 D OP

Cleaning 2 Out let water header

Free from dirt

Water spray

120 D OP

Cleaning 3 Vacuum Gauge

Free from mist & dirt

Wiping 60 W OP

Inspection 4 Vacuum Gauge

Within the indicated value range

Visual 30 D OP

Inspection 5 Bolts Tightened Tight all bolts

1200 M OP

Inspection 6 V. Pump belts gaurd

Tightened Tight all bolts

1200 W OP

Cleaning 7 Lubrication point

Free from dirt, grease & lubricant

Waste cloth

600 D OP

Lubrication

8 Shaft bearing

Top Up Grease MP3

60 W OP

Inspection 9 Repullper & drive gear box.

Cut in Tyre , Oil seal leakage

Visual 600 W OP

Cleaning 10 Drains No blockage

scrapping mud

3600 D OP

Vacuum pump(Causticizing Plant)

Cell -: Causticing Plant Equipment -: Mud Filer AreaArea

Sample Cleaning, Checking and Lubrication Standard


No.

Point Main responseClean

Lubricate ReplaceRestore

1 Is there any dirt or dust in the oil inlet? O2 Do the oil level indicators show adequate

levels?O

3 Can the oil level indicators be clearly seen? O4 Are there crack in the oil tank? O5 Is the oil tank bottom dirty? O6 Is the oil in the tank dirty? O7 Is there any oil leakge from the tank? O O8 Are oil levels adequate? O9 Is the correct type of oil being used? O

Cleaning / Inspection Check-list


Cleanliness - ObservationArea / Object

• Floor, Walls, Windows• Doors, Ceiling• Tables, Chairs• Equipments• Pipelines• Electric fittings• Carpets, Curtains• Pantry, Tea room, Toilet

Standard

• No dirt ,dust, stain • No leakage / overflow -

air, oil, water, grease• No cobwebs• No bad odor• Not broken• Not slippery• ……..


5S Job Cycle Chart

Deptt. Production: Assembly. EngineEntered by X & Y Date: 1 Feb 2006

No. 5S job

Sort

Set in order

Shine

Standardize

Sustain

A (Continuous)

B (Daily M

)

C (Daily E)

D (W

eekly)

E (Monthly)

F (O

ccasionally)

1 Red Tag Strategy (Occasional) O O 2 Red Tag Strategy (Repeated) O O 3 Place Indicators (Check or Make) O O 4 Item Indicators (Check or Make) O O

5Amount Indicators (Check or Make) O O

6 Sweep around line O O 7 Sweep within line O O 8 Sweep around worktable O O 9 Sweep on and under worktable O O


Standardization• Upto the previous stem only the machinery / equipment was the concentration. However in this step the surroundings of machinery are organized. Necessary items should be organized, such that there is no searching and searching time is reduced. • Work environment is modified such that there is no difficulty in getting any item. • Everybody should follow the work instructions strictly. • Necessary spares for equipments is planned and procured.


Autonomous Management• OEE (Overall Equipment effectiveness) and other TPM targets must be achieved by continuous improvement through Kaizen.

• PDCA (Plan-Do-Check-Act) cycle must be implemented for Kaizen.


The autonomous maintenance CAPD Cycle

Step 1Perform Initial cleaning

Check equipment and expose irregularities

C

Step 2Control contamination sources and improve inaccessible place

Act against contamination sources and inaccessible places

A

Step 3Establish cleaning and checking standards

Plan and do checks based on standards

P.D

Step 4Perform general equipment inspection

Repeat the C→A→P→D cycle for each category

Step 5General process inspection

Repeat the C→A→P→D cycle for each category

Step 6Systematize autonomous maintenance

C→A→P→D→C→A→P→D

Step 7Practice full self-management

C→A→P→D→C→A→P→D


Sample manual on exposing Seven steps of abnormality

Abnormality Examples1.Minor Flaws

• Contamination• Damage• Play• Slackness• Abnormal

phenomena• Adhesion

Dust, dirt, powder, oil, grease, rust, paintCracking, crushing, deformation, chipping, bendingShaking, failing out, tilling, eccentricity, wear, distortion, corrosionBelts, chainsUnusual noise, overheating, vibration, strange smells, discoloration, incorrect pressure or currentBlocking, hardening, accumulation of detins, pecking malfunction,

2.Unfulfilled Basic Conditions• Lubrication• Lubricant supply• Oil level gauges• Tightening

Insufficient, dirty, unidentified, unsuitable, or leaking lubricantDirty, damaged or declared lubricant inlets, tautly lubricant pipesDirty, damaged, leaking; no indication of correct levelNuts and bolts: slackens, missing, cross-threaded, too long, crushed, corroded, washer unsuitable, wing nuts on backward



Abnormality Examples3.Inaccessible Places

• Cleaning• Checking

• Lubricating

• Tightening• Operation• Adjustment

Machine construction, covers, layout, footholds, spaceCovers, construction, layout, instrument position and orientation, operating-range displayPosition of lubricant inlet, construction, height, footholds, lubricant outlet, spaceCovers, construction, layout, size, footholds, spaceMachine layout: position of valves, switches, and levers; footholdsPosition of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges, etc.

4.Contamination sources• Product • Raw

materials• Lubricants• Gases• Liquids

• Scrap• Other

Leaks, spills, spurts, scatter, overflowLeaks, spills, spurts, scatter, overflowLeaking, spilt, and seeping lubricating oils, hydraulic fluid, fuel oil, etc.Leaking compressed air, gases, steam, vapors, exhaust tumes, Leaking, spilt and spurting cold water, hot water, half-finished products, cooling water, waste water etc.Flashes, cuttings, packaging materials, and nonconforming productContaminations brought in by people, fork-lift trucks, etc. and infiltrating through cracks in buildings.



Abnormality Examples5.Quality Defect Sources

• Foreign matter• Shock• Moisture• Grain size

• Concentration• Viscosity

Inclusion, infiltration, and entrainment of rust, chips, wire scraps, insects, etc.Dropping, jolting, collision, vibrationToo much, too little, infiltration, defective eliminationAbnormalities in screens, centrifugal separators, compressed-air separators, etc.Inadequate warming, heating, compounding mixing, evaporation, stirring etc.Inadequate warming, heating, compounding mixing, evaporation, stirring etc.

6.Unnecessary and no-urgent items• Machinery• Piping equipment • Measuring

instruments• Electrical

equipment• Jigs and tools• Spare parts• Makeshift repairs

Pumps, fans, compressors, columns, tanks, etc.Pipes, hoses, ducts, valves, dampers, etc.Temperatures, pressure gauges, vacuum gauges, ammeters, etc.Wiring, piping, power leads, switches, plugs, etc.General tools, cutting tools, jigs, molds, dies, frames, etc.Standby equipment, spares, permanent stocks, auxiliary materials, etc.Tape, string, wire, metal plates, etc.



Abnormality Examples7.Unsafe places

• Floors

• Steps

• Lights

• Rotating machinery

• Lifting gear• Other

Unevenness, ramps, projections, cracking, peeling, wear (steel deck plates)Too steep, irregular, peeling anti-slit covering, corrosion, missing handrailsDim, out or position, dirty or broken covers, not properly explosion-proofedDisplaced, fallen of broken covers, no safety or emergency stop devicesWires, hooks, brakes, and other parts of cranes and hoistsSpecial substances, solvents, toxic gases, insulating materials, danger sings, protective clothing, etc.


Procedure for developing general inspection training program

B

Establish general inspection categoris

Prepare training materials

Schedule training

Train group leaders

Prepare for “relay teaching” of group members

Train group members

Group leaders

Group leaders; workplace supervisors

Maintenance staff

Maintenance staff and workplace supervisors

Maintenance staff

Maintenance staff check sheets

Manual

(e.g. Nuts, bolts, lubrication system, pneumatics, hydraulics, drives systems, electrics, etc.

Cutaway models, wallcharts, slides, etc.)

(General inspection of model equipment)

Conduct general inspection

Group members

A C

Train

Prepare

(General inspection of all equipment)


Procedure for developing general inspection training program

(Deteriorated parts; inaccessible areas)

Hold group meetings, list abnormalities, plan actions

Group members

Group members; maintenance personnel

Correct abnormalities

Abnormalities lists

Group members

Group members

Group members

Workplace supervisors; maintenance staff

Establish provisional daily inspection standards

Assess inspection skills

Perform self-audit and apply for official audit

Perform audit

Treat problem areas indicated

Group members; maintenance personnel

Provisional standards

Skill assessment charts

(On completion of each category)

(Practical tests)

Move to next inspection category approximately one category per month

A B C

General inspection

General inspection

Reinforcement


Step 4: Conduct general inspections

Key Step 4 activities

Learn the structure & functions of your own equipment (training by leader)

Test your understanding & then actually inspect the equipment

Correct new problems you find

Establish thorough visual controls to help control equipment conditions

Action and visual control


FUGAI STATUS OF MUD FILTER AREA

31 33

15 11

1518

106

1615

55

0

10

20

30

40

50

60

70

Mar-07 Apr-07 May-07 Jun-07

Number of fugaicarry over to nextmonthNumber of FugaiEliminated

Number of Fugais(identified+carryover)

Effect of Autonomous Maintenance

Fugai means abnormality identified by Red or White Tagging


Oil lubricant pipe Placed outside as No visual aid Provided.

Visual aidProvided to ensure continuousflow of oil for better lubricationof journal bush.

Examples

BEFORE

AFTER


VISUAL AID

Working range Max& Min. provided on all gauges for better Process control

Examples


All the open hot water lines were insulated to maintain a safe working environment.

Examples


BEFORE AFTER

Examples

Temporary pipes were provided to prevent the water splashing as the vacuum in the Tray was not sufficient enough

The Vacuum valve was changed & Vacuum intensity in Tray increased; all the temporary pipes removed.


Lubrication identification

Lub oil-1 Lub oil-2

Lub oil-3

Documents

4-Autonomous Maintenance 06 Sept 2007