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© 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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Best Practices and Operational Standards for Operators
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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Best Practices and Operational Standards for Operators
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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Best Practices and Operational Standards for Operators
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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Best Practices and Operational Standards for Operators
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
40 © Lean & Mean Consulting. All rights reserved. 2016