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5 S

Total productive Maintenance

Autonomous Maintenance

- Step 0

Introduction Total Productive

Maintenance

Definition: A structured approach that establishes a corporate culture, that will maximise production system effectiveness

Aim of TPM:

Prevent losses and achieve:

Zero Accidents

Zero defects

Zero Breakdowns

in the entire production system life

TPM:

Total Involvement of all functions and

people at all levels of organisation

Productive Efficient and effective

utilisation of all resources

Maintenance Keeping the man-

machine-material system in optimal

condition

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

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 N 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 0

Step 0 - Initial Preparation

Problems and equipment abnormalities cannot be clearly seen when the workplace is unorganized.

Cleaning and organizing the workplace helps the team to uncover problems.

Making problems visible is the first step of improvement.

5s is a foundation program before the implementation of TPM

To make the workplace organised and neat, 1S and 2S needs to be implemented

Step 0 1S Sorting the Work Place

1S (Seiri/Sorting)

- 1.) Classify necessary & unnecessary tools and equipment around Work Station

- 2.) Clear out unnecessary items, take them to salvage area or store

- 3.) Sort: - Hand Tools - Gauges - Equipment Accessories - Spares - Cupboards and work

tables

Step 0 1S Sorting the Work Place

1S (Seiri/Sorting)

Step 0 1S Sorting the Work Place

Decision Matrix

Step 0 2S Organising the Work Place

2S (Organising)

- 1.) Decide the right place for each necessary item (location)

- 2.) Mark the locations by drawing a boundary around the equipment to indicate its zone

- 3.) Exhibit: - Equipment Running - Job Change - Tool Change - Break Down

Step 0 2S Organising the Work Place

2S (Organising)

Summary

1S Sorting

Classify needed and unneeded items in

work area

Clear out unneeded items in work area

Autonomous Maintenance

Operator takes ownership of his/her equipment at all times

Establish basic conditions of equipment

2S Organising

Create a place for every needed item in

workplace

Pre-fixed locations of tools and

equipment

Standardise the item location and sustain

it