autonomous maintenance webinar - industry forum · what is autonomous maintenance? a process to...
TRANSCRIPT
• During presentations (12:30 – 13:00) everyone will be muted so that only the presenter will be heard.
• The presentation will be followed by a Q&A session. Click on the hand symbol to show that you have a question or type your question in the question box.
• 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
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
Select Model MachineAM Team
Maintenance staffManagers
Trial LubricationAM Team
Maintenance Staff
Identify
Draft Provisional Standards
for Cleaning & Inspection
Step 3 – Inspection and Lubrication
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