Total Productive Maintenance

AUTONOMOUS MAINTENANCE
Step II

“Ownership
Ownershipthroughthrough
Mini Company & TPM
Minicompany &1 TPM ”
 TIM PENYUSUN MODUL

Edwar Laudin, Edison Chrisnanto

(Produksi Line 1)

Ownership through Mini Company & TPM

 TATA GRAHA

Jadwal Acara
(Waktu) No Smoking

Snack Toilet

.
Please..
Hand Phone/Pager Pintu Darurat

OFF / Silent

Ownership through Mini Company & TPM

 SASARAN PELATIHAN

Peserta dapat memahami cara pelaksanaan

Total Productive Maintenance-
Autonomous Maintenance Step II

Ownership through Mini Company & TPM

 AGENDA PELATIHAN
1. Sumber kontaminan
2. Manfaat menghilangkan sumber kontaminan
3. Contoh penerapan dalam menghilangkan sumber kontaminan
4. Audit Step 2 AM

Ownership through Mini Company & TPM

 STEP-STEP DALAM MENJALANKAN AM

7 STEP 4 TAHAPAN
perawatan menjadi operator yang
mandiri kompeten
7 Perawatan mandiri penuh 4 Dapat memperbaiki peralatan
Management &
6 organisasi tempat kerja Mengerti hubungan antara
akurasi peralatan dengan
5 Pemeriksaan mandiri 3 pengendalian kualitas produk

4 Pemeriksaan umum
Mengetahui fungsi dan
Pembuatan standardard 2 struktur peralatan/mesin
3 pembersihan & pelumasan
Menghilangkan sumber kontaminasi &
2 area yang susah dijangkau
Dapat melihat cacat.
Menguasai pola pikir dan cara
1 melaksanakan improvement
1 Pembersihan awal
peralatan

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 Menghilangkan Sumber Kotoran/
STEP- 2
Kontaminasi & Area Susah dijangkau

Pola Pikir

Mengapa harus terus mengerjakan pembersihan

kalau sumber kotoran dan sumber kontaminasi
dapat dihilangkan

Yuk kita kotorin lagi biar

operator capai membersihkan
Memangnya operator
kamu anggap tidak
punya otak , . . apa !

Ownership through Mini Company & TPM

 Bagaimana bisa tahu
kalau ada cacat atau
kebocoran
Mesin dalam keadaan kotor
kebocoran-kebocoran ,
goresan-goresan ,
kondisi abnormal dan cacat lain
tidak mudah diketahui

Cacat atau
kebocoran mudah
diketahui

Mesin dalam keadaan bersih

kebocoran-kebocoran ,
goresan-goresan ,
kondisi abnormal dan cacat lain
akan mudah diketahui

Ownership through Mini Company & TPM

 Aktivitas :
• Stop kontaminasi dari sumbernya
• Modifikasi peralatan untuk memudahkan dan
mempersingkat waktu pembersihan dan pelumasan
• Gunakan jendela pemeriksaan untuk memudahkan
pemeriksaan

Improve
Improve Area-nya
Cegah kotoran dari Susah dicapai
supaya pelumasan
luar mengotori mesin
mudah dilakukan .

Tujuan :
->Mencegah kotoran muncul kembali sehingga aktivitas
pembersihan bisa dikurangi
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 Menghilangkan Sumber Kontaminasi

Sumber Kontaminasi :
– Fluid leaks (kebocoran)

– Poor containment (wadah material tidak memadai)

– Poor 5S practices (5R yang tidak baik)

– Work area spills (tetesan/kebocoran dari mesin)

– Poor filtration (filtrasi/penyaringan yang jelek)

– Poor work pride (Malas)

– Environment (lingkungan)

Ownership through Mini Company & TPM

 Dengan Tag
sebanyak ini
Dengan Tag mesinnya pasti
masalah mudah sakit berat
dilihat
dan dikontrol

• Tag warna dasar merah

Penanggulangan oleh bagian “ Maintenance “

• Tag warna dasar putih

Penanggulangan oleh “ Small group AM “

Ownership through Mini Company & TPM

 Before & after

Ownership through Mini Company & TPM

 Before & after

Ownership through Mini Company & TPM

 Before & after

Ownership through Mini Company & TPM

 Processing Equipment
AM Audit Step II

Ownership through Mini Company & TPM

 Jishu-Hozen Review Sheet (Processing Equipment)-2
Area / Team Submission Area manager Team leader
Jishu-Hozen Review Request
date
Equip. Unit No.
Jishu-Hozen Review Sheet Score: pt. Pass Fail
Date requested for review
Step 2: Contamination Sources and Hard-to-Access Pass levels :Score = total score for Review Items 1-
Areas(Processing Equipment) Actual date / Time of review 6
Review Area Senior Self Area M. Senior M.
Self Name of reviewer
type Manager Manager 90 or over 85 or over 80 or over
Rath
Quite Comment
Poor er Fair Good
Review Item Key Points to Review good s
poor
2 pt. 4 pt. 6 pt. 8 pt. 10 pt.
1. Sustainment of Step 1 - Cleaning levels achieved in Step 1 (Initial Cleaning) being properly sustained?

2. Countermeasures for main body of -

Sources of dirt, dust, oil leaks, air leaks, etc. all plotted on a chart, and action
equipment taken to rectify them?
-Hard-to- access areas all marked on a chart, and creative improvements
implemented to make them more accessible (guarding improved, original
cleaning tools devised, everything sorted and reorganised)?
3. Countermeasures for peripheral devices Sources of dirt, dust, oil leaks, air leaks, etc. all plotted on a chart, and action
taken to rectify them?
-Hard-to- access areas all marked on a chart, and creative improvements
implemented to make them more accessible (guarding improved, original
cleaning tools devised, everything sorted and reorganised)?
4. Countermeasures for equipment Sources of dirt, dust, oil leaks, air leaks, etc. all plotted on a chart, and action
surroundings taken to rectify them?
-Hard-to- access areas all marked on a chart, and creative improvements
implemented to make them more accessible (guarding improved, original
cleaning tools devised, everything sorted and reorganised)?
5. Improvement and sustainment Lubrication points clearly labelled according to lubrication standards, so that
anyone can lubricate the machines correctly?
6. Status of activities -All team members actively involved?
- Plenty of original thought going into the improvements?
Points 2 4 6 8 10
Comprehensive
Also implemented in
1- Hardly implemented at Only implemented in Implemented in specific lubrication achieved;
Equipment more difficult and less
Scoring 5 all obvious places locations hardly any outstanding
obvious places
key issues
Operators taking part, Responsibilities clearly
Only maintenance staff Operators doing nearly
6 People No interest at all but doing the easy defined, and everything
and supervisors active all the work
tasks only being done properly
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4 - 67 - a
 Kesimpulan

• Sumber kontaminan dan kotor perlu dihilangkan supaya mengurangi

aktivitas pembersihan

Ownership through Mini Company & TPM

Ownership through Mini Company & TPM