Autonomous Maintenance

Webinar

• During presentations (12:30 – 13:00) everyone will be muted so that only the presenter will be heard.

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• Recording will be made available after the webinar on the Industry Forum website.

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What is Autonomous Maintenance?

A process to restore equipment to its optimum condition

A process to involve equipment users in the autonomous management of their equipment

Research has shown that between 70% and 95% of equipment failures are due to the forced deterioration of equipment

Restoration is the process of removing abnormalities caused by forced deterioration and preventing their recurrence

Why do we need to restore equipment?

Why do we need autonomous management?

Lean manufacturing require teams to respond to customer demands as quickly and flexibly as possible

This is only possible through autonomous management of their processes and equipment

Key AM concepts

• Forced Deterioration

• Chronic Losses

• Sporadic Losses

What is Forced Deterioration?

Equipment deteriorates - ‘things wear’

If we don’t maintain and operate equipment properly then it deteriorates faster – forced deterioration

What do the effects of forced deterioration look like?

• Contamination from product or process debris• Minor damage - Bent Parts/Tooling, minor

cracks• Wear and Vibration• Leaks - air/water/steam/lubricant• Overheating• Missing items• Loose fastenings• Corrosion

Chronic and sporadic losses

Hidden abnormalities which result in chronic losses (reduction in performance and quality)

A failure is the tip of the iceberg!

Expose hidden abnormalities and

prevent quality and functional failures

before they happen

Failures

Wear, play, slackness, leakage, dust, dirt, corrosion,

deformation, adherence of raw materials, surface damage, cracking,

overheating, vibration, noise, and other abnormalities

Sporadic Losses (Breakdowns)

A view of equipment loss

Poorly managed equipment

Deterioration

Chronic losses Sporadic losses

Abnormalities

Unnoticed or ignored

Lost availability, performance and

quality

The eight steps of Autonomous Maintenance

Step 2 - Eliminate sources of contamination and difficult to clean and inspect areas

Step 3 – Create and maintain cleaning, inspection & lubrication standards

Step 4 – General Inspection

Step 5 – Autonomous Inspection

Step 6 - Standardisation

Step 7 – Autonomous Management

Step 1 – Initial Cleaning

Step 0 – Preparation

Phase 1

Phase 3

Phase 2

The purpose of the phases

Phase 1 Restore equipment

Phase 2 Upskill AM teams

Phase 3 Develop Autonomous Management

Step 0 - Understand the equipment

Organisation

4. Add notes to help explain the function & sequence of operation of the mechanisms

Notes

Machine / Line

Issue No.

Date

1. Identify the key mechanisms involved in the investigation (follow the product flow)2. Study and develop an understanding of function and operatios of the mechanisms3. Draw diagrams to explain the function and operation

Created By

Process for developing mechanisms

Drawings

Equipment Function Worksheet

Step 0 Worksheet 1

feed funnel

motor

air injector

Step 1 – Initial Cleaning

Step 2 – Eliminate Contamination

Step 2 – Eliminate Contamination

Step 2 – Ease of Inspection

Select Model MachineAM Team

Maintenance staffManagers

Trial LubricationAM Team

Maintenance Staff

Identify

Draft Provisional Standards

for Cleaning & Inspection

Step 3 – Inspection and Lubrication

Step 3 – Inspection and Lubrication

Provisional Standard

One Point Lesson

Check Sheet

Implementation Tips• Choose a meaningful but manageable pilot:

• Equipment whose performance is important but not critical

• Common equipment where lessons learned can be duplicated

• Small enough to provide resource to follow up on corrective actions – target 8 weeks

Implementation Tips (2)• Choose a positive team:

• Good, stable team dynamics with good team leader

• Previous commitment to improvement activity

• Good skill balance

Thank you for attending