autonomous maintenance preview

© Lean & Mean Consulting. All rights reserved. 2015 © Lean & Mean Consulting. All rights reserved. 2016

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Autonomous Maintenance

Best Practices and Operational Standards for Operators

World-Class Standards & Best Practices of Operational Excellence

World-Class Standards & Best Practices of Operational Excellence

© Lean & Mean Consulting. All rights reserved. 2016

LEAN Management Academy - Outline Knowledge & Expertise / Editable Training Presentations / 16 Modules

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1. Understand the key concepts of TPM and Autonomous Maintenance activities

2. Learn how to implement the Autonomous Maintenance activities, step by step

3. Learn how to use activity boards, meetings and one-point lessons to promote TPM goals

4. Understand the critical success factors in sustaining Autonomous Maintenance activities on the shop-floor

Learning Objectives

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Machine failures have many hidden causes

Failure is what we see but is only the tip of the

iceberg

Minor machine defects are generally unnoticed but are

the cause of almost all machine failures

Loosening

Contamination Corrosion

Leaks

Flaws

Deformation

Vibration

Cracks Backlash

Improper Temperature Wear

Failure

Visible

Less Visible

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What is TPM?

Total Productive Maintenance (TPM) is a method to achieve maximum equipment effectiveness through

employee involvement

Management + Operators + Maintenance

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TPM Principles

Increase Overall Equipment Effectiveness (OEE)

Upgrade operations and maintenance skills

Employee involvement through small group activities

A fact-based approach to continuous improvement

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TPM is a paradigm shift 1

Old Attitude TPM Attitude

I use You maintain & I fix

Operator Maintenance

We maintain !

Old Philosophy New philosophy

I operate, you fix, he designs. . .

Quality is costly. . .

Supervisors & engineers are experts. . .

Defects, speed losses & unplanned downtime are inevitable…

Inventory is useful

We are all responsible for our equipment.

Quality is free.

Operators/Maintenance are experts too.

Zero defects, zero speed losses, zero unplanned downtime.

Inventory is costly.

TPM is a paradigm shift 2

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Module. 12

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What is Autonomous Maintenance?

Autonomous Maintenance is maintenance performed by operators

Basic maintenance that can be easily performed on a daily basis, e.g. inspection, cleaning, lubrication, etc.

Learning about the equipment to understand how it works and be able to spot signs of trouble

An employee engagement program as part of the Lean/TPM initiative

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AM is a paradigm shift

Old Attitude TPM Attitude

I use I maintain & I fix

We maintain

Maintenance Operator Maintenance Operator

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AM facilitates a culture change

Work Systems & Processes

Behavior

Attitude

Culture

Changes the way we act…

And the way we think…

By improving equipment and processes…

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Characteristics of AM Programs

Organization-led activities Supported by company and TPM Promotion Office

Use of audits Determine full implementation of each step

Provide feedback on strengths and weaknesses

Clarify what needs to be achieved and best way to do it

Use of Activity Boards

Meeting and reports

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Goals of Autonomous Maintenance

Goals of Autonomous Maintenance

Prevent Equipment

Deterioration

Equipment Restoration &

Proper Management

Establish Basic Conditions

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Natural & Forced Deterioration

Deterioration is what leads equipment to break down or generate defective parts

Natural Deterioration – Normal wear caused by parts rubbing against one another

Forced Deterioration – Deterioration that happens sooner than it would naturally. Usually caused by our failure to do something we ought to. Examples:

Not keeping parts clean and lubricated

Ignoring excessive loads in moving parts

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Autonomous Maintenance Approach

Source: Adapted from Society for Maintenance & Reliability Professionals

Check

Act Plan

Do

Examine & expose problems

Counter & solve problems

Execute & follow standards & rules

Prevent recurrence through improvement

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Module. 12

Key Concepts

Shop-floor based activities

Operator conducted

Operator enhancing

Team activity

Autonomous Management

TPM Foundation

Part of the job!

3 Key Tools

Activity Board

Meetings

One Point Lessons

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Activity Board

Activity board is a visual tool to guide teams to action

Basic elements of problem solving: 1. What are we going to do? (Theme)

2. Why are we going to do it? (Vision)

3. How far are we going to go? (Targets)

4. How are we going to do it? (Method)

5. What is the sequence and timing of actions? (Schedule)

6. Who does what? ( Roles)

7. What results do we expect? (Assessment)

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Example 3: A.M. Activity Board

Step 2: Sources of Contamination

People Results

Definition

Team Mission

Layout of Line & Identified Important Areas

Safety Hazard

Contamination

Hard-to-reach

Main Failure

• Team Name • Members

Line

• Mission • Objectives

Activity & Findings

Step 1: Initial Cleaning

Pictures Before After

Tag List Production Maintenance

Tag Movement

Actual Tags

Display actual findings from Initial Cleaning such as trash, unnecessary items, dust and other contamination

Explain and show Focused Improvement activities for sources of contamination

One-Point-Lessons

Team

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Components of an Activity Board

1. Team organization and company’s vision

2. Ongoing results

3. The theme

4. Current situation and causes

5. Actions to address the causes

6. Log of targets achieved, remaining problems and actions planned to resolved them

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Activity Board & Daily Standup Meetings

Agenda

• Yesterday’s issues

• Lessons learned

• Manpower status

• Update from top management

• Lean/TPM activities

• Today’s target & actions

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What is One-Point Lesson?

One-point lesson is a 5-10 min self-study lesson drawn up by team members

Lesson covers a single aspect of equipment or machine structure, functioning, cleaning, lubrication, inspection or tightening method

Is a highly effective tool because it is short and focused on a topic

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One-Point Lessons as a Cascading Training Tool

Team members are responsible for training each other

Teaching promotes effective leadership and accountability

One-point lessons – a teaching tool that is short and to the point

Follow up to see what has been taught is practiced

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Types of One-Point Lessons

1. Basic Knowledge Lesson

2. Examples of Problems 3. Examples of Improvement

• Training tool designed to fill in knowledge gaps

• To ensure team members have consistent knowledge they need for daily production and TPM activities

• Lessons are focused on equipment subsystems, safety points, or basic operating information

• Based on problems that have already occurred, these lessons are designed to communicate knowledge or skills to help operators prevent similar problems from happening in the future

• To ensure that successful improvement ideas are used widely, these lessons present what needs to be done to prevent or correct equipment abnormalities

• It describes the approaches, actions, and results of specific improvement projects

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Dept.

Manager

Super-

visor

Team

Leader

Created

by

Basic

Knowledge

Improvement

Example Trouble Cases

Date

Executed

Instructor

Subj

ect Compressed Air Usage

For Line #1 & 2

TPM One-Point LessonNo.

Date of

CreationNovember, 2010

DL4301

David

Clas

sific

atio

n

Tom

Actio

n Hi

stor

y

Mark Paul

1. Compressed Air may only be used on the Dribbler Scale ONLY

2. Scale Area is currently Hard-To-Reach and may cause variable weight if not cleaned

1

2

Don’t Make A Bigger Mess !!!

Example: One-Point Lesson

One-Point Lesson is a tool with the following characteristics:

One sheet… To share the results of autonomous study… For 5-10 minutes

Contents can be knowledge and skills of:

Equipment

Safety

Operation process

Task

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Module. 12

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7 Steps of Autonomous Maintenance

1. Clean and inspect

2. Eliminate problem sources and inaccessible areas

3. Draw up cleaning and lubricating standards

4. Conduct general inspections

5. Conduct autonomous inspections

6. Standardize through visual workplace management

7. Implement autonomous equipment management

Source: Autonomous Maintenance for Operators by JIPM

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Step 1 – Clean and inspect

Eliminate all dirt and grime on the machine, lubricate and tighten bolts

Find and correct problems

Implement the Activity Board and the 4Ms

Address operators’ questions during education process

Develop countermeasures to mis-operations as early as possible

Eliminate all sources of dirt and grime on the machine, lubricate, tighten bolts, and find and correct problems

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Initial Cleaning is the Foundation of Autonomous Maintenance

Cleaning is inspection

Inspection is finding problems

Problems demand restoration to original proper conditions and improvement to prevent recurrence

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When You Find a Problem, Tag It!

Attach a tag to each problem you expose so that it won’t be forgotten

Fix problems as soon as possible and remove the tag

Draw up plans for resolving problems that can’t be addressed immediately

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Step 2 – Eliminate problem sources and inaccessible areas

Correct sources of dirt and grime

Prevent spattering

Improve accessibility for cleaning and lubrication

Establish time targets for cleaning

Establish tentative standards

Correct sources of dirt and grime; prevent spattering and improve accessibility for cleaning and lubrication. Shorten the

time it takes to clean and lubricate.

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Step 4 – Conduct general inspections

How to develop general inspection

Overall inspection procedures and sub-steps

Preparing inspection education

Conducting overall inspection education

Set tentative inspecting standards

Restore and improve equipment

Lubrication

• Color-coded marks to indicate oil inlets

• Oil level and supply interval labels

• Indication of upper and lower oil level limits

• Indication of oil consumption per standard time unit

• Color-coding on oil cans to indicate oil types

Equipment elements

• “Inspected” marks and math marks

• Color-coding (blue) on bolts reserved for adjustment by maintenance personnel only

• Color-coding (yellow) on holes that do not require bolts

Suggestions for Visual Controls

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Example: Use of Match Marks

Match marks are placed on bolts and nuts so that operator can easily detect if bolts have been loosen due to excessive vibrations. These are being placed on critical bolts after each bolt had received their correct torque.

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Step 5 – Conduct autonomous inspections

Prepare standard check sheets for autonomous inspections

Define autonomous chart / schedule for each operator

Carry out the inspections

Use new methods of cleaning and lubricating

Prepare standard worksheets for autonomous inspections. Carry out the inspections.

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Checklist for Daily Operator PM

1. Check coolant level through clear Plexiglas

2. Check heat exchanger fans (strings should be moving)

3. Check servo drive fans (string should be moving)

4. Check heat exchanger air filter (change when dark)

5. Check servo drive air filter (change when dark)

6. Check way lube reservoir (add when low)

7. Check main motor air filter (change when dark)

8. Check main motor cooling fan (string should move)

9. Check mist collector motor and air filter (change when dark)

10. Check bar feeder hydraulic motor air filter

11. Check bar feeder hydraulic oil level (add when low)

Example: Checklist for autonomous inspections

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Module. 12

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How to Sustain AM?

Active leadership for TPM initiative

AM is owned by Production department and supported by Maintenance department

Proper operator training, education and skills certification

The time required for cleaning and lubrication must be included in the daily schedule

Supervisors need to ensure that AM activities are performed

autonomous maintenance preview

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