3 - 4 - MAINT MANAG 2021-22 TPM IVa Autonomous Maint

MAINTENANCE MANAGEMENT - Chapter 3 - TPM
4. Autonomous Maintenance.
1
Autonomous Maintenance : Key Points

It is the main way production workers participate in TPM.
SHARED RESPONSIBILITY OF MAINTAINING ”BASIC CONDITIONS” OF

EQUIPMENT BETWEEN PRODUCTION AND MAINTENANCE
Purpose
1. Brings production & maintenance people together to
 slow routine deterioration and

 halt accelerated deterioration
2. Helps operators learn more about their equipment (the cause and effect)
3. Prepares operators to be active partners with maintenance and
engineering in improving equipment performance and reliability
2

 Daily/Time-Based Maintenance
– Cleaning
– Lubrication
– Tightening
 Daily inspection by using 5 SENSES
 Right operation, right adjustment, right setting
“I operate, You fix.” “We are AlI responsible

for Our equipment.”
Source: BMW MT Training 0305
“I operate, You Clean.” “We are AlI responsible for

cleanliness of Our line.”
3
Shift in Attitudes
Operator Maintenance Operator Maintenance
I use I maintain & We maintain

I fix
Conventional TPM
4
The 7 steps of Autonomous Maintenance

 Step 1: Increase operator knowledge
• Empower operators with the knowledge on how to operate and maintain the
equipment that they are assigned to use.
• Equip them with knowledge on how the parts of the equipment come together so
that they know which parts need periodic maintenance and which parts need to be
looked after when it comes to cleaning, lubrication, etc
3 Years
 Step 2: Initial cleaning and inspection : “Restoration”

• Detect problems of lines and restore its original state.
• Start managing the line autonomously. ( 5S, Minor Stops, Quality )
• Create & perform temporary “Cleaning/Lubrication procedures.”
 Step 3: Eliminate sources of contamination and inaccessible

areas
• Solve “Sources of Contamination” and
• “Hard to Reach” areas. (Cleaning, Inspection, Lubrication)
5

 Step 4: Develop and test cleaning, inspection, and lubrication
standards
• Develop tentative standards for cleaning, lubrication and inspection.
• Based on manufacturer’s specifications in order to maintain its “like new” quality
and level of performance
3 Years
• Use checklist tools that can help guide operators on what to perform, how to
perform those maintenance tasks, as well as notify them to remind them when a
task is due
 Step 5: General inspection and inspection procedures training

• To reinforce good practices like autonomous maintenance, it is recommended to
conduct inspection and monitoring.
• Operators themselves can inspect their equipment and provide information in the
form of inspection reports with photos on the current condition of the equipment
and maintenance tasks fulfilled.
• Data collected through these inspections can be monitored to ensure that all
equipment are maintained by operators and in good working condition.
6

 Step 6: Standardize Autonomous Management and Visual Aids
• In the sixth step of the A.M., the objective is to implement the "Time-Based
Maintenance" (TBM) system, integrated in Autonomous Maintenance, to achieve
"0" defects in work equipment.
• Make it easier for operators to complete maintenance tasks by implementing the
use of visual cues such as color-coded tags and easy-to-understand signs or
3 Years
posters that remind operators and other workers of steps to follow when working
with or being around equipment.
• Create visual aids of the standards from step 4 to help operators follow and
reinforce standards for maintaining equipment and machines.
 Step 7: Ongoing autonomous maintenance and continued

improvement
• One of the pillars of TPM is improvement and as processes and equipment
change, as well as the operators that handle equipment, there is good reason to
establish continuous improvement for autonomous maintenance.
• Any training feedback gathered from operators in step 1, as well as inspection and
monitoring data collected through their reports in step 5 can be used to
continuously improve procedures for equipment maintenance.
7
3 Key Tools for Autonomous Maintenance
Key Concepts 3 Key Tools
 Shop floor based activities • Activity Board

 Operator conducted
 Operator enhancing
 Team activity
• Meetings
 Autonomous Management
 TPM Foundation • One Point Lessons
 Part of the job!
Source: BMW MT Training 0305 8

A.M. One Point Lessons
One Point Lesson is a tool with TPM One-Point Lesson
the following characteristics; No. DL1034
Air Breather of
Subject
Compressor Date of
November, 2003
Creation
 One sheet Dept. Super- Team Created
Classification
Manager visor Leader by
 to share the results of Basic Improvement Trouble

John Jerry Paul Daniel
autonomous study Knowledge Example Cases
 for 5-10 minutes
Contents can be knowledge

and skills of;
 Equipment
 Safety
 Operation Process Date
Action History
Executed
 Task Instructor
Trainee
9
A.M. Activity Board – Example 1
Activity & Findings Treasures
People
Team Team Mission •Display actual findings from
Step 1: Initial Cleaning Initial Cleaning such as trash,
•Team Name •Mission unnecessary items, dust and
•Members •Objectives Definition other contamination.
Step 2: Sources of Contamination

Pictures Before After
Explain and show Focused

Line Improvement activities
for sources of contamination
Layout of Line &
Identified Important
Areas
Tag List Production Maintenance
Safety Hazard One-Point-Lessons
Contamination
Tag Movement
Hard-to-reach
Actual Tags
Main Failure
10
Inte-
grantes Indica- Mapa de la
Roles Indicador dor máquina
Diagra-
Productividad Seguir- (Elementos
ma dad Sistemas)
Paso 1
Seguridad
Misión
(Operando
Indicador Indicador Limpiando)
Calidad Entregas
apalacioposada@Gmail.com
Visión 100 cm
Indicador Indicador Estándar

Cronograma
Costos Motivación (Limpieza
Paso 1
Inspección
UPL’s Seguimiento
Source: Alvaro Palacio Posada
F F Lección de anomalías F F
un punto
120 cm
11
12
A.M. The Five S

The Five Steps of Housekeeping
1. Sort: Separate out all that is unnecessary and eliminate it.
2. Store: Put essential things in order so they can be easily accessed.
Everything has a place… and is in its place. And visual management.
3. Shine: Clean everything – tools and workplaces – removing stains,
spots, debris (waste) and eradicating sources of dirt. Bring everything
to “NEW” and better than new.
4. Standardize: Standardize the previous three steps to make the process
one that never ends and can be improved upon.
5. Sustain: Make cleaning and checking routine.

13
A.M. What to detect during Initial Cleaning?
“Categories of Abnormality”
S: Safety Items : safety area, spot, work environment
1: 5 S Related Items:
 Sort: Unnecessary items
 Store: Disorganized storage, Lack of Visual Indications
 Shine: Cleanliness/Preserve
2: Sources of Contamination:
 Leaks, Spills
3: Hard-to-Reach area
4: Broken/Missing Parts
5: “Basic Conditions”:
 Lubrication
 Tightening
 Cleaning & Inspection
6: Quality Related: Causes of defect
See “JISHU HOZEN” presentation on Atenea for further information 14
A.M. Initial Cleaning - Examples
Before After
15
A.M. : F-Tagging
During Afterwards –
Initial Cleaning Every Day Process
The F standing for fuguai, the Japanese word for abnormality

16
A.M. : Monitoring Tags

• Initial Cleaning is not an one time event. It should be repeated monthly.
• The more restoration you continue, the less Initial Cleaning time you will need.
250
Tag
200 Issued
Tag
150 Restored
Number of Tags
100
50
17
18
A.M. : Major Impact from Initial Cleaning Activity

• 10 % increase in Machine Time by cleaning and adjustment of
cylinders and air tubes of Bag Former
(13 cycle/min to 15 cycle/min)
19
A.M. : 5S Audit Checks

Three purposes of conducting regular 5S Audit reviews are:
• Review compliance to the 5S standards for your factory
• Note and address non-compliance – to fix what is wrong!
• Provide a formal opportunity to suggest improvements
Source: https://ganeshmrgn.wordpress.com/2015/04/28/5-s/
• Without audits, it is impossible to ensure compliance.
20

How often should audits be Performed?
Regular audits lead to the best results:
 Weekly “self-check” audits by teams of workers, reviewing their own areas
• This might be the best way to generate suggestions for improvements
 Monthly audits by the area supervisor
• Ensure that the weekly audits catch any problems with the daily or weekly
cleanups
• Pay special attention to the less-frequent cleaning tasks
• Try to notice what is missing: new tools that do not yet have a place in a rack;
materials stored neatly but not well-labeled
 Quarterly audits by the plant manager
• Ensure that standards are being met
• If there are deficiencies, ask “why”: try to determine the root causes
• Ensure that resources are allocated to repairs and to making the long-term
improvements. 21

22
23
3. Autonomous Maintenance
Additional Information
24
Extension of 5th step of A.M. : GENERAL INSPECTION

The objective of the 5th step is to improve the availability of the machine by
performing GENERAL INSPECTIONS, in order to eliminate the deterioration of the
machine: both accelerated and natural.
To do this, it’s necessary to understand the structure, functions and principles of
operation of the equipment.
Workers must be trained to carry out this task, training them in maintenance on:
• Clamping, fastening, tightening and adjustment elements
• Lubrication systems
• Power transmission systems
• Electrical (eg motors) and control systems (eg sensors, detectors)
• Develop the ability to detect modes of equipment failure
25
Extension of 5th step of A.M. : GENERAL INSPECTION

Training must be carried out at the pace that allows all workers to acquire the
necessary knowledge and skills. This usually takes a lot of time because not
everyone learns just as quickly.
The training begins with attendants and section heads and ends with less skilled
operators.
Until all the personnel are not formed, they can not begin to carry out the
General Inspections.
26
Extension of 6th step of A.M. : STANDARDIZE AUTONOMOUS MANAGEMENT

AND VISUAL AIDS
In the sixth step of the A.M., the objective is to implement the "Time-Based
Maintenance" (TBM) system, integrated in Autonomous Maintenance, to achieve
"0" defects in work equipment.
It is about strengthening planned maintenance with the lowest possible cost,
through an autonomous inspection.
In this step, the activities to be carried out are:
• Review and improve Safety, Cleaning, Lubrication and Inspection standards.
You must have a single standard procedure for both Planned and
Independent Maintenance.
• Raise staffing levels and increase skills in inspection and early detection of
failures, explaining the particular function of each piece of equipment to
help understand the equipment as a logical system and not as a simple set
of assembled parts. 27

AND VISUAL AIDS
In this step, the activities to be carried out are (cont.):
• Establishment of visual controls that allow a continuous monitoring of the
deterioration conditions that are presented in the different components of
the equipment, without having to stop the machine for it.
• Maintain optimum operating conditions of equipment, reducing equipment
maintenance costs by at least 20%, implementing improvements that extend
the life of consumable components.
• Ensure proper maintenance by preventing human errors (eg. Poka-Yoke)
28
AND VISUAL AIDS
Organization and order are the fundamental activities to improve, encourage,
simplify and organize autonomous maintenance, and compliance with standards
and procedures.
it is necessary to ensure compliance with standardization and quality.
After this step, the operators detect failures, prevent them, keep the equipment at
a basic level and it can be affirmed that they begin to "produce quality".
In this step, operators should be trained about Quality, involving all departments
of the company:
• Quality specifications, causes of poor quality and interpretation of results, as
well as the relationship between these aspects.
• Criteria for Quality Assurance.
29
Extension of 7th step of A.M. : IMPLEMENTATION OF A.M. and CONTINUOUS

IMPROVEMENT
A well-functioning self-contained maintenance system must also be "self-
managed" by the workers.
The A.M. must act as a train with its own energy and that does not depend on the
locomotive of the managers. The workers will follow the example of middle
managers and managers, as regards their determination, power of action and
support of A.M.
The autonomous "administration" of A.M. is achieved by implementing the
following operating rules:
• Total participación of workers.
• History and compliance activities must be clearly visible (A.M. boards).
• Enjoy the achievements.
30
Extension of 7th step of A.M. : IMPLEMENTATION OF A.M. and CONTINUOUS

IMPROVEMENT
At the end of the activities of the working groups for the implantation of M.A.,
the workers are real professionals, independent, specialists capable of generating
their own work and of improving the equipment and the manufacturing process.
In this last step, the objectives of:
Zero Accidents & Zero Breakdowns
Operators of M.A. are those who can most help in the process of improving OEE
because they are the ones who know the equipment’s weaknesses better.
The whole process of the seven steps of M.A. is slow and can take between 3 and
5 years from general cleaning to full implantation.
31

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MAINTENANCE MANAGEMENT - Chapter 3 - TPM

Autonomous Maintenance : Key Points

SHARED RESPONSIBILITY OF MAINTAINING ”BASIC CONDITIONS” OF

 slow routine deterioration and

Autonomous Maintenance : Key Points

 Daily inspection by using 5 SENSES

 Right operation, right adjustment, right setting

“I operate, You fix.” “We are AlI responsible

“I operate, You Clean.” “We are AlI responsible for

Autonomous Maintenance : Key Points

Operator Maintenance Operator Maintenance

I use I maintain & We maintain

The 7 steps of Autonomous Maintenance

 Step 2: Initial cleaning and inspection : “Restoration”

 Step 3: Eliminate sources of contamination and inaccessible

The 7 steps of Autonomous Maintenance

 Step 5: General inspection and inspection procedures training

The 7 steps of Autonomous Maintenance

 Step 7: Ongoing autonomous maintenance and continued

3 Key Tools for Autonomous Maintenance

Key Concepts 3 Key Tools

 Shop floor based activities • Activity Board

Source: BMW MT Training 0305 8

 One sheet Dept. Super- Team Created

 to share the results of Basic Improvement Trouble

autonomous study Knowledge Example Cases

 for 5-10 minutes

Contents can be knowledge

Step 2: Sources of Contamination

Explain and show Focused

Indicador Indicador Estándar

A.M. The Five S

5. Sustain: Make cleaning and checking routine.

A.M. Initial Cleaning - Examples

The F standing for fuguai, the Japanese word for abnormality

A.M. : Monitoring Tags

A.M. : Major Impact from Initial Cleaning Activity

A.M. : 5S Audit Checks

• Without audits, it is impossible to ensure compliance.

A.M. : 5S Audit Checks

A.M. : 5S Audit Checks

Extension of 5th step of A.M. : GENERAL INSPECTION

Extension of 5th step of A.M. : GENERAL INSPECTION

Extension of 6th step of A.M. : STANDARDIZE AUTONOMOUS MANAGEMENT

Extension of 6th step of A.M. : STANDARDIZE AUTONOMOUS MANAGEMENT

Extension of 7th step of A.M. : IMPLEMENTATION OF A.M. and CONTINUOUS

Extension of 7th step of A.M. : IMPLEMENTATION OF A.M. and CONTINUOUS

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