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Total productive Maintenance

Autonomous Maintenance

- Step 2 Countermeasures for

Sources of Contamination & Hard to Access

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

TPM View

Operators

Baby Parents Physicians

Machines Maintenance

Aim

•Combat Sources of Dirt & difficult to reach spots

•Improve accessibility

•Allow operators to find ways to improve the machine

•Allow them to enjoy the result of their work

•Allow them to share a sense of achievement w/ the whole

team

Activities

To detect the abnormalities related to Source of contamination and hard to

access and determine the places and types of them within the map.

Control Box

Induction Heating

Chamber

Plasma Cutting Chamber

Control Gears & Drive

Chamber

Air Supply Chamber

Chimney

N.º Item SOC HTA Description Action Responsible Date estimated Date of execution Observations 1 Excess dust in the

plasma cutting chamber Install a small

extraction fan Pieter 25/06/2013

Source of contamination

Hard to access

Correcting abnormalities

Its so much

easier to clean

the machine

now!!!

Improve the equipment to

minimize the need to clean

INSTALLING OF PLATES AND WINDOWS

FOR FACILITATION, INSPECTION AND

CHECKING

Now It's easy

to see Look…there is

misalignment of

the chain

CONTROL DIRT SOURCE

No dirt falls on

the floor

becasuse of

this guard

SRCE Tool

C

E

R

S

Eliminate: Is it possible to eliminate the

contamination source?

Combine: Is it possible to combine all the

contamination sources in just one place? To contain

them in just one place?

Replace: Can we substitute the material that causes

the dirt by another that does not do it? Is it possible to

change the hard to access accumulation?

Simplify: Can we simplify the method of cleaning the

places where dirt accumulates? Is it possible to

create new ways of cleaning? Vacuum cleaning,

washing, etc...

Visual Control Concepts

• to develop a visual language

• to avoid doubts

• to reinforce discipline

• to reduce inspection time

• to contribute for the safety

• to create facilities of training

• to guarantee basic conditions

Losses Reduction !

Visual control examples

Static Dynamic

Visual controls examples

Visual controls examples

Visual controls examples

Transparent guarding

Gauge marking

Flow Directions

Min&max level indication

Lighting system

Visual controls examples

Summary

Step 2

Autonomous Maintenance

• Operator takes ownership of his/her equipment at all times

• Establish basic conditions of equipment

• Operators become equipment experts