Total Productive Maintenance

tvv@narpavimc.com

+91-80889 98086
1
Autonomous
Maintenance
(Jishu Hozen)

2
Introduction to Autonomous Maintenance

Approach involves giving Operators bring equipment to

1 machine operators Operator 4 “Like New” standard by Machine
responsibility for basic upkeep
tasks
Self Care cleaning & inspecting Like New

Operators take care of

Maintenance Technicians
2 focus on more complex tasks Maintenanc 5 routine tasks and maintain Reduce
basic condition of the
e equipment Deterioration

Improve engagement of
employees at all levels – No Employee Reduced Breakdowns
3 blame games. Knowledge of 6 stoppages & defects Improve OEE
the equipment
Engagement

3
Why Jishu Hozen

1 2
To Make Operator To Eliminate Quality
Equipment “Expert” Defects

5 3 To Eliminate Cost Losses

To Prevent Equipment
Deterioration

4 To Maintain Equipment
in Optimal Condition
4
Introduction to Autonomous Maintenance
• Operators are closest to the equipment
• Maintenance can train operators
• A layer of protection to equipment failure
• OPLs come handy
Operator • Early equipment warning signs
Self • Collect critical evidence for failure
Care • Cleaning is Inspecting
• Cleaning, Lubrication, Inspection, Tightening

Why to Train Operators on Maintenance

• Front Line reliability (CLIT, My Machine Concept)
• Hazard Identification
• Root Cause Analysis (RCA)
• Problem Resolution support
• Visual Management (gauges, levels, meters, pipes, motors)
5
Introduction to Autonomous Maintenance

Equipment
Visual
Manageme
nt

Match-marking Direction of
Lubrication points rotation of motors, Color coding of
torqued fasteners pipes
pulleys, etc

Filter change
Oil Level Pressure
indicators Flow direction CIL Point
Indicators Range
visualization Descriptions
Visualization

6
6
Introduction to Autonomous Maintenance
• High Technology areas
• High Safety risk areas
• Planned Maintenance
Maintenanc • Predictive Maintenance
e • Corrective Maintenance
• OPLs to Operators
• Skills Training to Operators on AM

Predictive Maintenance Techniques

• Acoustic Analysis (leaks, cracks, etc)
• Infrared Thermography Analysis
• Oil Analysis
• Vibration Analysis
• Motor Circuit Analysis

7
7
Natural & Forced Deterioration

• Machine designed with Factor

of safety – Marginal Life
• Natural Deterioration – due to
natural end of machine
service life
• Forced Deterioration – due to
improper usage

8
8
Natural & Forced Deterioration

Natural Deterioration
–Extend Life Time

Planned
Forced Deterioration
Maintenance
–Eliminate Causes
- Prevent Errors
- Improve
Basic Conditions
Maintainability
Restoration
- Improve Safety &
- Cleaning
Reliability
- Lubrication
- Inspection
- Tightening

9
9
Forced Deterioration

Examples of Forced Deterioration

1. Looseness
2. Breakage
3. Wear & tear
4. Misalignment
5. Poor Wiring
6. Rust, Contamination
7. Oil Leak
8. Unwanted parts

10
10
Forced Deterioration

Activities to Prevent Forced Deterioration

1. Correct Operations, Improvement of basic conditions & adjustments
to prevent quality defects
2. Measure deterioration – by touch, see, hear and smell
3. Rectify deterioration – by continuously improving the CLIT &
Corrective actions

11
11
Time Based & Condition Based Maintenance

TBM is a maintenance strategy that involves scheduling

maintenance activities at regular, predetermined intervals
based on the equipment’s estimated lifespan

CBM is strategy that monitors the actual condition of an asset

to decide what maintenance needs to be done. CBM dictates
that maintenance should only be performed when certain
indicators show signs of decreasing performance or upcoming
failure

Predictive Maintenance “intelligent way to maximize machine

availability. Health check of the equipment, collect data & then
decide on the maintenance

12
12
7 Steps of Autonomous Maintenance

13
13
7 Steps of Autonomous Maintenance Step 0

14
14
7 Steps of Autonomous Maintenance Step 1

15
15
7 Steps of Autonomous Maintenance Step 2

16
16
7 Steps of Autonomous Maintenance Step 2

17
17
7 Steps of Autonomous Maintenance Step 3

18
18
7 Steps of Autonomous Maintenance Step 3

19
19
7 Steps of Autonomous Maintenance Step 4

20
20
7 Steps of Autonomous Maintenance Step 4

Visual Workplace

Prevent Abnormalities (Poke Yoke)

Visual Controls (Standards to wrorkplace,

Warn & Detect Abnormaities

Visual Display (Established Standards &

Information)

5S
7 Steps of Autonomous Maintenance Step 5

22
22
7 Steps of Autonomous Maintenance Step 6

• Training & Education

• Develop Equipment Related Skills
• Detect Abnormalities
• Restore & Correct abnormalities
• Set optimum machine conditions
• Maintain optimum machine conditions
• Establish AM schedule for each operator
• Review and meetings at activity board
23
23
7 Steps of Autonomous Maintenance Step 7

24
24
Considerations In Implementing Autonomous Maintenance

Objectives and benefits of Jishu Hozen Pillar

• Improved equipment performance and reliability
• Reduced maintenance costs and downtime
• Increased operator engagement and ownership of equipment
• Enhanced quality control and defect prevention
• Improved safety and environmental compliance
• Enhanced teamwork and communication between departments
Operator Involvement
Data-Driven Decision Making
Continuous Improvement
Collaboration and Teamwork Across Departments
Leadership Commitment and Support
25
25
Tools & Techniques used in JH

• Process Mapping: Visual representation of a process to identify areas for improvement and
streamline workflows
• Maintenance Software: Computerized Maintenance Management Systems (CMMS) for managing
and scheduling maintenance tasks
• Root Cause Analysis: Systematic approach to identifying the underlying causes of equipment
problems and developing solutions
• Kaizen: Continuous improvement approach that emphasizes small, incremental changes to
improve overall performance
• 5S Methodology: Workplace organization and cleanliness approach that improves efficiency and
reduces waste

26
26
General Formats in JH
No. Format / Template Focus Area Features
Ensures proper cleaning of
1 Cleaning Checklist
equipment and work area
Helps operators identify
2 Equipment Inspection Form potential equipment issues
before they become problems
Guides operators through the
3 Autonomous Maintenance Plan autonomous maintenance
process
Helps operators identify and
Root Cause Analysis (RCA)
4 address the underlying causes
Form
of equipment failures
Assesses the overall health of
5 TPM Audit Checklist TPM implementation and
identifies areas for improvement
Metrics
Frequency of cleaning, cleaning
completion rate
Number of issues identified, number
of issues resolved
Completion rate of autonomous
maintenance tasks
Number of RCAs completed,
percentage of issues resolved at the downtime, reduces maintenance costs,
root cause level
Audit score, number of identified
improvement opportunities
Benefits
Reduces equipment breakdowns and
downtime, improves overall equipment
effectiveness
Prevents equipment breakdowns and
downtime, reduces maintenance costs
Improves equipment reliability, reduces
maintenance costs, increases operator
engagement and ownership
Prevents equipment breakdowns and
promotes continuous improvement
Guides continuous improvement efforts,
ensures consistent implementation of TPM
principles, improves overall equipment
effectiveness
27
27
General Formats in JH
6 Standardized Work Instructions
7 Visual Management Board
8 Improvement Proposal Form
9 Process Mapping Template
10 Daily Management Checklist
Provides clear instructions for
Task completion time, Reduces errors and defects, improves
operators to perform their tasks
defect rate productivity, promotes continuous improvement
consistently and effectively
Equipment uptime,
Provides a visual representation of Promotes collaboration and teamwork,
maintenance completion
equipment performance, maintenance facilitates data-driven decision making,
rate, improvement project
status, and improvement opportunities improves overall equipment effectiveness
completion rate
Number of improvement
Encourages operators to suggest and Promotes continuous improvement, increases
proposals submitted,
implement small, incremental operator engagement and ownership,
number of proposals
improvements improves overall equipment effectiveness
implemented
Maps out the steps involved in a Promotes continuous improvement, identifies
Process cycle time, defect
particular process, helping to identify waste and non-value-added activities,
rate, value-added time
improvement opportunities improves overall process efficiency
Provides a checklist of tasks for
Completion rate of daily Improves equipment reliability, promotes
operators and supervisors to complete
management tasks, consistent daily management, reduces
each day, promoting consistent and
equipment downtime downtime and maintenance costs
effective daily management
28
28
KPI Measurements in JH

•Equipment Availability: The percentage of time that equipment is available for use

•Equipment Performance: The percentage of time that equipment operates at its

maximum capacity

•Equipment Quality: The percentage of products produced that meet quality

standards

•Maintenance Cost: The cost of maintaining equipment

•Mean Time Between Failures (MTBF): The average time between equipment failures

•Mean Time To Repair (MTTR): The average time it takes to repair equipment
29
29
tvv@narpavimc.com

+91-80889 98086

30