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Total Preventative Maintenance Autonomous Maintenance
Step 0 and 1 (Part 2) Program Initiation
Ea
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Sa
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5 S
Cleaning and inspection marks the crucial start of the Jishu Hozen activities.
Cleaning helps to find what is wrong with the equipment.
The three main points to remember about cleaning and inspecting are:
Cleaning is inspection.
Inspection means finding problems.
Problems leads to either restoration or improvement.
Gemba walks and Layered Audits are vitally important. The purpose of these management tools are to ensure compliance. Failure from management to do these activities will result in 1 & 2 S system failures. Visuals to be close to machinery or on display boards purpose built for the area Summary objective of Step 0 • Assisting workers to understand how equipment deterioration occurs • Understanding safety critical actions • Ease in identifying abnormal conditions
Inadequate cleaning is often the cause of equipment malfunctioning and quality problems.
Examples are:
• Dirt on clutches and work pieces in automated equipment can affect the workflow, cause
malfunctions and minor stoppages.
• In electroplating, contaminated work pieces or dirt in the electrolyte can cause plating
defects.
• In Paint shops contamination from one department can find its way to another
Before abnormalities are hidden by a machine covered in grit and grime
After abnormalities are uncovered and the machine can be properly maintained
• Tools to convey information regarding equipment knowledge and skills, regarding trouble or improvement cases.
• Designed to help enhance knowledge and skills in a short period of time.
• To upgrade the level of expertise of the whole team.
One Point Lessons are:
One Point Lessons act as learning`s for others in the organization.
• The basic principle is for individual
members to personally think, study
and prepare a sheet with originality.
• Explain its content to team members.
• Thereafter, conducting free
discussions on the spot to make the
issue clearer and unquestionable.
Details for documentation control.
Prepared by, the date and the theme heading
Hand drawn explanation of what and how to grease nipple
Hand drawn explanation how to use the grease gun
Tagging is the visual representation of abnormalities in equipment. The tagging
speeds up the removal of abnormalities.
White Tags- If the operators are able to correct abnormalities
themselves then a white tag is located at the
abnormality.
Red Tags- Where red tags are located at abnormalities, the
maintenance personnel are
required to action.
Once the abnormalities are
rectified, the relevant tags will be removed.
Equipment Name..................................................
Control Number:....................................................
Date of Detection:..................................................
Detected by:............................................................
Description of Minor Defects:...............................
..................................................................................
..................................................................................
Total Productive Maintenance
White Tags
Equipment Name..................................................
Control Number:....................................................
Date of Detection:..................................................
Detected by:............................................................
Description of Minor Defects:...............................
..................................................................................
..................................................................................
Total Productive Maintenance
Red Tags
White Tags
• White Tags show Issues that the Team Member can
sort out themselves.
• Red Tags require expert maintenance support
• All this information is captured in a tag register to
ensure closing of issues and traceability
Red Tags
Shows information such as
• Equipment Name
• Control Number
• Date Detected
• Detected by
• Description of defect
1. Minor Flaws
2. Unfulfilled basic conditions
3. Inaccessible places
4. Contamination sources
5. Quality defect sources
6. Unnecessary and non urgent items
7. Unsafe places
Minor Flaws.
Contamination. Dust, dirt, powder, oil, grease, rust, paint.
Damage. Cracking, crushing, deformation, chipping, bending.
Play. Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion.
Slackness. Belts, chains.
Abnormal Phenomenon. Unusual noise, overheating, vibration, strange smells, discoloration,
incorrect pressure.
Adhesion. Blocking, hardening, accumulation of debris, peeling, malfunction.
Unfulfilled Basic
Conditions.
Lubrication. Insufficient, dirty, unidentified, unsuitable leaking.
Lubrication Supply. Dirty, damaged or deformed lubricant inlets, faulty lubricant pipes.
Oil level gauges. Dirty , damaged, leaking, no indication of correct level.
Tightening. Nuts and bolts slackness, missing, cross-threaded, too long, crushed,
corroded, unsuitable washers, wing nuts on backwards.
• Aim and benefit of One Point Lessons and tagging of abnormalities
is to prevent forced machine breakdown
• Forced machine breakdown is caused by the listed abnormalities
Inaccessible Places.
Cleaning. Machine construction, covers , layout, footholds, space.
Checking. Construction, covers, layouts , footholds, instrument position and
orientation, operating range display.
Lubricating. Position of lubricant inlet, construction, height, footholds, lubricant
outlets.
Tightening. Covers, construction, layout size, space.
Operation. Machine layout, position of valves, switches and leavers,
footholds.
Adjustments. Position of pressure gauges, thermometers, flow meters, moisture
gauges, vacuum gauges.
Contamination
Sources.
Product. Leaks, Spills, Spurts, Scattering, Overflow.
Raw Materials. Leaks, Spills, Spurts, Scattering, Overflow.
Lubricants. Leaking compressed air, gases, steam, vapors, exhaust fumes.
Liquids. Leaking water, Hot Cold, half finished products, waste water,
leaking supply lines.
Scrap. Flashes, cuttings, packaging materials and non conforming
product.
Others. Contaminants by people and forklifts, infiltration through cracked
walls, broken windows.
• Aim and benefit of One Point Lessons and tagging of abnormalities
is to prevent forced machine breakdown
• Forced machine breakdown is caused by the listed abnormalities
Quality Defect Sources.
Foreign Matter. Dust, rust, powder, chips, moisture, wire, scraps, wood pieces,
paper pieces, stones.
Shock. Dropping, Jolting, collision, vibration.
Moisture. Too little of too much infiltration.
Gain Size. Abnormalities in screens, compressed air separators, centrifugal
separators.
Concentration. Inadequate warming, heating, compounding, mixing, evaporation,
stirring.
Viscosity. Inadequate warming, heating, compounding, mixing, evaporation,
stirring.
Unnecessary and Non-
Urgent Items.
Machinery. Pumps, fans, compressors, columns, tanks.
Piping Equipment. Pipes, hoses, ducts, valves, dampers.
Measuring Instruments. Temperatures, pressure gauges, vacuum gauges, ammeters.
Electrical Equipment. Wiring, piping, power leads, switches, plugs.
Jigs and Tools. General tools, cutting tools, jigs, dies, frames.
Spare parts. Standby equipment, spares, permanent stock, auxiliary materials.
Makeshift Repairs. Tape, string, wire, metal plates.
• Aim and benefit of One Point Lessons and tagging of abnormalities
is to prevent forced machine breakdown
• Forced machine breakdown is caused by the listed abnormalities
Unsafe Places.
Floors. Unevenness, cracked, holes, projections, peeling, wear of steel
chucker plates, slipping.
Steps. Too steep, irregular, slipping, missing handrails.
Lights Dim, out of position, dirty and broken covers, no explosion proofing.
Rotating Machinery. Displaced, fallen oil or broken covers, not safe for emergency,
missing emergency stop devices.
Lifting Devices. Wires, hooks, brakes and other parts of cranes and hoists.
Others. Special substances, solvents, toxic gases, insulating materials,
danger signs, protective clothing.
Hindsight Engineering; if only we had…..
Clean and inspect the
selected equipment – make use of the 5 senses
and record the cleaning time.
Determine the abnormalities – make use of the 7 types of Abnormalities.
Locate tags on abnormalities.
Prepare a list of unfilled
basic conditions.
Compile a list of hard to
clean, lubricate, tighten,
inspect and adjust.
Carry out an audit on the
1st Step.
Carry out a meeting after
the daily activities.
Directional flow indicators Operational range
Revision 1 2014/01/14
TPM Training Schedule
Participants: AIDC Team, Senior Management Team, Production Team.
Aim: To present the fundamentals of Autonomous Maintenance and start
company’s journey through Total Productive Maintenance.
Training Schedule:
Step 0 theory 30 Minutes
Step 0 practical training 1 Hour
Step 1 theory 1 Hour
Step 1 practical training 1.5 Hours
Step 1 closing and findings discussion 30 Minutes
Followed up with daily cleaning and weekly meetings
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