Autonomous Maintenance

AM-SW RTT CIL With Routes DMS

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 PILLAR: AM Pillar Review Date: August 8, 2012 Version: August 24, 2012
1. System Owner: Plant CIL DMS Owner 2. Process Name: 3. Products of the System:
CIL Management System CIL schedule for task execution
4. Business Customer/Requirements: 5. Customers: 6. Customer Requirements:

To effectively identify defects to prevent unplanned downtime and maximize stable uptime through Cleaning, Inspecting and Lubrication procedures on the right frequency in the most efficient and time effective manner. Operating Departments

7. Process Measures: 8. Results Tracking:

Process Output Measures: Unplanned stops and planned downtime for CIL's met Score Card Run Chart Other

9. Process Flow Chart 10. Process Maintenance Chart

Equipment Operator MMIS Owner Day Leader ShiftLeader DMS Owner Output Measures Process Monitoring

Monitoring Control or Action

Measures Who Monitors? Frequency Limits Who Investigates?
Develop CILs and linked supporting documentation (OPL's, Lube Maps) through AM activities, Initiatives including frequency, test time,modified and obsolete tasks Complete health
checks monthly O1

Generate & print Unplanned stops Line Leader Weekly Phase Target Line Leader
Enter/ Display list of
change/ list of tasks for
tasks for FL1 - shift by line &
obsolete FL5(current &
Is additional task(s) route(s) 7 O2
information new)
5 Planned downtime for CIL routes Line Leader Weekly Phase Target Line Leader
needed to
perform
task?
Create routes No O3
Address gaps No Can all tasks BDE Line System
& assign tasks Leave Is the Breakdowns/line Weekly Against target Line Leader
task and develop be done in Owner
task as is plan through the allotted
new?
DDS process downtime?
Retrieve supporting
documentation linked to Yes
the CIL from doc system1 Yes In Process Measures Process Monitoring
No Monitoring Control or Action Who Investigates?
Execute Is start Measures Who Monitors?
date
Frequency Limits
task(s) to
standard known? Are the P1
correct
resources CIL and Q tasks complete on time Line Leader Weekly <100% Line Leader
Yes available?
No
Bring up a list of P2
tasks that were Enter start
date Yes Defects found through CIL/line Line Leader Weekly <85% Line Leader
done based on 6
the routes that
were executed
2 Validate effort hours vs. P3
Monthly (to cover all
time available for routes Health audit score Dept DMS Owner areas) <100% Plant DMS Owner

Yes Review list P5

Is a and
Mark CIL validate CIL and Q tasks completed Line Leader Weekly <100% Line Leader
as defect defect
found? assignment
3
Distribute as
No part of DDS
process
Go to DH Mark
flowchart complete
4

Yes
Were all of Yes Were the CILs
the tasks executed to
completed? the standard?

No
No

Were any Yes

of these Q Done
tasks?

No

No
Were the tasks Enter the amount of
completed in Review tasks not completed and
time it took to change scheduling as necessary
the scheduled complete the route
window? 8
11

Verify all Q tasks

Yes were completed
9

No Critique task
Did the execution based
route fit into on feedback
scheduled
window?

Yes
Yes Is change
Change needed to
task(s) content of
CIL?
Does the Yes
CIL content
need any
changes? No

No
Yes
Done Change Does the task
route(s) need to be
assigned to a
different route?

No

Yes
Is change to
Chagnge task
start date scheduling
10 needed?

No

Done
CIL
Output Measures
# of unplanned stops/line/day

Planned downtime for CIL Route

In Process Measures
% CIL (including Q tasks) tasks completed on time

Defects Found through CIL/Line

Breakdowns/Line

% CIL tasks (including Q tasks) complete

= unplanned stops X 1440
scheduled time

Sum of all CIL tasks within routes which are due for the past month which have the "D" for execute while down checked

= # CIL's for line done by due date during the shift X 100
# CIL's due by line during the shift

= # defects found through CIL's by line for the shift X 100

# defects found by line for the shift

Get from the BDE DMS - in this DMS how is "Line" defined and should the definition be the same in CIL/CL/CO, etc. as it
is in BDE

= # CIL's for line which were completed w/in shift X 100

# CIL's for line open @ beginning of shift + # of new CIL's opened which were due in the shift
In Process Measure(s) Output Measure
XXX Module XXX Module

50
55
60
65
70
75
80
85
90
95
100
12
15
18
21
24
27
30
33
36
39

0
3
6
9
5-Sep

12-Sep

19-Sep

26-Sep

3-Oct

10-Oct

17-Oct

24-Oct

31-Oct

7-Nov

14-Nov

21-Nov

28-Nov

5-Dec

12-Dec

19-Dec
Stops/day

26-Dec

2-Jan

9-Jan

16-Jan

CIL EXECUTION - % Completion 23-Jan

System Owner: Name of the Department System Owner
CIL EXECUTION DMS
 On-Going Health Check In Proces
XXX Module X

35
40
45
50
55
60
65
70
75
80
85
90
95
100
35
40
45

5-Sep 5-Sep

12-Sep 12-Sep

19-Sep 19-Sep

26-Sep 26-Sep

3-Oct 3-Oct

10-Oct 10-Oct

17-Oct 17-Oct

24-Oct 24-Oct

31-Oct 31-Oct

7-Nov 7-Nov

14-Nov 14-Nov

21-Nov 21-Nov

28-Nov 28-Nov

5-Dec 5-Dec

12-Dec 12-Dec

19-Dec 19-Dec

26-Dec 26-Dec

2-Jan 2-Jan

9-Jan 9-Jan

16-Jan 16-Jan

23-Jan 23-Jan
CIL EXECUTION - DMS HEALTH CHECK
etion
30-Jan

6-Feb

System Owner
13-Feb

20-Feb
N DMS
27-Feb

6-Mar

13-Mar

20-Mar

27-Mar

3-Apr

10-Apr
12
Needs to be
updated - 16 July
 H CHECK
30-Jan 30-Jan

6-Feb 6-Feb

13-Feb 13-Feb

20-Feb 20-Feb

27-Feb 27-Feb

6-Mar 6-Mar

13-Mar 13-Mar

20-Mar 20-Mar

27-Mar 27-Mar

3-Apr 3-Apr

10-Apr 10-Apr
 Pillar DMS's Scorecard - Plant x
IN PROCESS MEASURES MONITOR
Data
DMS or
Sampling Process # Process Definition
In- Process
Targets
Who Monitors

1 D

2 D

3 D

4
D

D
5
S

6
D

7
 D
8
D
rd - Plant x L Not on Track J Done / On Track

In-Process Health (FY 07/08)

MONITORING PROCESS
Quarter 1 Quarter 2 Quarter 3

Reporting Q1 Q2 Q3
Monitoring Action or Rating Guidelines Q1 Q2 Q3
Who İnvestigates Hierarchy In-Process In-Process In-Process
Frequency Control Limits (Smiley Face) Status Status Status
Level Measure Measure Measure

J
J

J
L
 Done / On Track

07/08) OUTPUT MEASURES

Quarter 4 (Business / Customer Measures)

Q4 Reporting
Q4 Tracking Rating Gidelines
In-Process Output 'Measures Indicators Hierarchy Rating Status
Status Frequency (Smiley Face)
Measure Level

J
L