autonomous maint trg

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Presentation on

Total Productive Maintenance

Presentation on

Total Productive Maintenance

Autonomous Maintenance Pillar

TQM International Pvt. Ltd. 52 Community Centre, 2nd Floor, East of ailas!, "e# $el!i%&&' '(5



B0!"#$%%&'! %() *resentation in +*-+*/

SHARING OF KNOWLEDGE ON AUTONOMOUS MAINTENANCE



B0!"#$%%&'! %() *resentation in +*-+*

Autonomous Maintenance - Background

I Operate, You Maintain Wide gap in set

of mind of operation & maintenance

people

Poor/ no Analytical Approac

Inade!uate "raining



B0!"#$%%&'! %() *resentation in +*-+*1

$evelo) Process * E+ui)ment com)etence

)erators to en!ance )roductivity-e o)erate -e maintain

-e toet!er -I" , toet!er L/E is P!iloso)!y

Esta0lis!ment of self manaement at

circle levels

To ma1e all o)erators a#are of loss,

cost * ne# tec!ni+ues

Autonomous Maintenance - AIM



B0!"#$%%&'! %() *resentation in +*-+*2

Wat is Autonomous Maintenance#

Autonomous Maintenance is most important activity and performed

by operator themselves.

The operators (From Production Department) themselves take up the

ownership of the euipment for the maintenance.

The principle of !" operate# and !" maintained# is adopted.

(AM is geared towards developing operators to be able to take care of

small maintenance tasks and upkeep of their equipment to prevent

from deterioration. The maintenance persons are made free so thatthey spend time on more value added activity and Technical repairs.)



B0!"#$%%&'! %() *resentation in +*-+*3

$oals of Autonomous Maintenance#

The $oals of Autonomous Maintenance is to keep the plant operatin$efficiently by dealin$ with euipment abnormalities promptly so as to

meet production tar$ets without any breakdowns. This is achieved by%

& Preventin$ euipment deterioration throu$h daily checks

& 'estorin$ euipment to ideal state.

& stablishin$ basic conditions for upkeep of the euipment

& se of euipment as a means of teachin$ people new ways of

thinkin$ and workin$.



B0!"#$%%&'! %() *resentation in +*-+*

Step-2 Eliminate source of contamination and inaccessible places to reduce

time for cleaning, checking and lubricate

Step-3 Establish cleaning, Inspection & lubrication standards to keep

equipment in peak optimal conditions and stop deterioration

Step-4 Developing equipment competent operator through

training for general inspection

Step-5 Developing process competent operatorfor general inspection through training

Step-6 Systemize Autonomous aint!

through standardisation

Step-7 "ull self management

at circle levels

Step-1 #erform Initial $leaning to eliminate dirt,dust, grime and e%pose all abnormalities

%teps of Autonomous Maintenance



B0!"#$%%&'! %() *resentation in +*-+*4

ules for Implementation of ' steps of

Autonomous Maintenance

Autonomous Maintenance activities are implemented insteps and are only effective if pro$ressed from one step to

ne*t step in strictly controlled manner.

'e$ular Auditin$ must be conducted before proceedin$ tone*t step of AM.



B0!"#$%%&'! %() *resentation in +*-+*"

(irst step of Autonomous Maintenance

"nitial cleanin$% "t consist of removin$ all dust+ dirt+ $rime+ oil+ $rease+

other contaminants to euipment for e*posin$ hidden defects.

(,ip possible Failure in the bud)



B0!"#$%%&'! %() *resentation in +*-+*!0

)ey Points for *leaning

-leanin$ is a form of inspection in TPM+ so as to e*pose hidden

defects and abnormality in euipment.

-leanin$ is %& 'e$ular practice as a part of daily work & 'emoval of layer of $rime& Dust dirt in all attachment and accessories& "nvesti$ation of sources of contamination.



B0!"#$%%&'! %() *resentation in +*-+*!!

)ey Points of Inspection

-leanin$ as inspection means detectin$ abnormalities/defects in

euipment so as to restore into workin$ condition.

"is means+

& 0earchin$ visible defects i.e. looseness vibration+ overheatin$.& 0earchin$ worn out $ullies+ belts+ block filters etc.

& 0earchin$ easy method to lubricate operate and ad1usts& nsurin$ all meters operate correctly and clearly marked with

specific value.& 0earchin$ any leaka$es of product+ steam+ water+ oil+ compressed

air & Also searchin$ hidden problems such as corrosion+ insulatin$

material and blocka$es.



B0!"#$%%&'! %() *resentation in +*-+*!/

armful affects on inade!uate cleaning



B0!"#$%%&'! %() *resentation in +*-+*!

Wat is aily *ecking#

0tandards and one point lesson should be drawn up for daily checks.

-heck sheets are meanin$ful and in true sense daily inspection should

be carried accordin$ly.

0ome of the e*amples checks could be%

*eckpoints for .uts and Bolts



B0!"#$%%&'! %() *resentation in +*-+*!1


u0rication ceckpoints



B0!"#$%%&'! %() *resentation in +*-+*!2


"ransmission %ystem ceckpoints



B0!"#$%%&'! %() *resentation in +*-+*!3


ydraulic units



B0!"#$%%&'! %() *resentation in +*-+*!


Pneumatic ceckpoints



B0!"#$%%&'! %() *resentation in +*-+*!4


1lectrical ceckpoints



B0!"#$%%&'! %() *resentation in +*-+*!"


*eckpoints for $eneral-Purpose e!uipment



B0!"#$%%&'! %() *resentation in +*-+*//

Initial cleanup of macines

& 0upervisor and technician should discuss and set a date for

implementin$ step& Arran$e all items needed for cleanin$

& Bn the arran$ed date+ employees should clean the euipment

completely with the help of maintenance department.

& Dust+ stains+ oils and $rease has to be removed.

& Followin$ are the thin$s that has to be taken care while cleanin$.They are Bil leaka$e+ loose wires+ unfastened nits and bolts and

worn out parts.

-ontdC



B0!"#$%%&'! %() *resentation in +*-+*/

& After clean up problems are cate$oried and suitably ta$$ed.hite ta$s is place where problems can be solved by operators.

Pink ta$ is placed where the aid of maintenance department is

needed.

& -ontents of ta$ is transferred to F">A" 'e$ister.

& Make note of area which were inaccessible.

& Finally close the open parts of the machine and run the machine.

Initial cleanup of macines



B0!"#$%%&'! %() *resentation in +*-+*/1

*ounter Measures +

& "naccessible re$ions had to be reached easily. .$. "f there are

many screw to open a fly wheel door+ hin$e door can be used."nstead of openin$ a door for inspectin$ the machine+ acrylic

sheets can be used

& To prevent work out of machine parts necessary action must be

taken.

& Machine parts should be modified to prevent accumulation of dirt

and dust.



B0!"#$%%&'! %() *resentation in +*-+*/2

"entati2e %tandard

& ;< schedule has to be made and followed strictly.

& 0chedule should be made re$ardin$ cleanin$+ inspection and

lubrication and it also should include details like when+ what and

how.



B0!"#$%%&'! %() *resentation in +*-+*/3

$eneral Inspection

& The employees are trained in disciplines like Pneumatics+

electrical+ hydraulics+ lubricant and coolant+ drives+ bolts+ nuts and0afety.

& This is necessary to improve the technical skills of employees and

to use inspection manuals correctly.

& After acuirin$ this new knowled$e the employees should share

this with others.& 6y acuirin$ this new technical knowled$e+ the operators are now

well aware of machine parts.



B0!"#$%%&'! %() *resentation in +*-+*/

Autonomous Inspection

& ,ew methods of cleanin$ and lubricatin$ are used.

& ach employee prepares his own autonomous chart / schedule inconsultation with supervisor.

& Parts which have never $iven any problem or part which donEt

need any inspection are removed from list permanently based on

e*perience.

& "ncludin$ $ood uality machine parts. This avoid defects due to poor ;<.

& "nspection that is made in preventive maintenance is included in

;<.

& The freuency of cleanup and inspection is reduced based on

e*perience.



B0!"#$%%&'! %() *resentation in +*-+*/4

%tandardi3ation

& pto the previous stem only the machinery / euipment was the

concentration. <owever in this step the surroundin$s of machineryare or$anied. ,ecessary items should be or$anied+ such that

there is no searchin$ and searchin$ time is reduced.

& ork environment is modified such that there is no difficulty in

$ettin$ any item.

& verybody should follow the work instructions strictly.& ,ecessary spares for euipments is planned and procured.



B0!"#$%%&'! %() *resentation in +*-+*/"

Autonomous Management

& B and BP and other TPM tar$ets must be achieved by

continuous improve throu$h aien.& PD-A ( Plan+ Do+ -heck and Act ) cycle must be implemented for

aien.



B0!"#$%%&'! %() *resentation in +*-+*0

"e autonomous maintenance *AP *ycle



B0!"#$%%&'! %() *resentation in +*-+*!

%ample manual on e4posing %e2en steps of a0normality



B0!"#$%%&'! %() *resentation in +*-+*/

%ample manual on e4posing %e2en steps of a0normality



B0!"#$%%&'! %() *resentation in +*-+*

Procedure for de2eloping general inspection training program

A



B0!"#$%%&'! %() *resentation in +*-+*1

Procedure for de2eloping general inspection training program

A

T! / /t t A M3



B0!"#$%%&'! %() *resentation in +*-+*2

T!e /even /te)s to A.M3

/te)%& Activities 4ard#are oals /oft#are oals 6ole ofManaers 7 /taff

InitialCleanin

# Eliminate dust 7rust 7 dirt frommain e+ui)ment.

# E8)osea0normalitiessuc! as sli!tdefects, source of

contamination,!ard to access)laces, sources of+uality defects.

# Prevent forceddeterioration 0yelimination ofdust 7 dirt.

# 6aise +uality ofc!ec1in andre)air #or1.

# 6educec!ec1in 7cleanin 7 re)airtime.

# Esta0lis! 0asice+ui)mentconditions

# E8)ose and deal#it! !iddendefects.

# $evelo) o#ner%s!i) and 1no#%!o# ofe+ui)mentamono)erators.

# $evelo)

leaders!i) 0y/A 9/mall rou)

Activities:.

# Peo)le are a0leto see sli!tdefect and ot!erirreularities.

# E8)lain effects ofdust 7 dirt 7 rust.

# Point out t!eim)ortant )arts to0e 1e)t clean and0asic e+ui)mentconditions.

# Teac! usae ofmanuals on nuts,0olts, lu0rication.

# E8)lainins)ection iscleanin.

Contd.

T! / /t t A M3



B0!"#$%%&'! %() *resentation in +*-+*3


/te)%2 Activities 4ard#are oals /oft#are oals 6ole ofManaers 7 /taff

$evelo)counter%measures

# 6educecleanin time0y eliminatinsources.

# Preventscatterin of

oils andcuttins.

# Address !ardto accessareas.

# Increase intrinsiccleanin 0y)reventin dust 7dirt and controllinat sources.

# Increase

maintaina0ility 0yim)rovincleanin, c!ec1inand lu0ricatin.

# Create e+ui)mentt!at does notre+uire manual#or1.

# Teac!continuousim)rovement one+ui)ment 0ysmallim)rovements.

# $evelo) /A.# Let )eo)le en;oy

success of selfcreation.

# Encouraeim)rovement 0y)rovidinuidance.

# Teac! )ro0lemsolvin

tec!ni+ues.# ive uidance on

use of visualcontrols.

Contd.

T! / /t t A M3



B0!"#$%%&'! %() *resentation in +*-+*


/te)%< Activities 4ard#are oals /oft#are oals 6ole ofManaers 7 /taff

Esta0lis!tentativestandards

# Formulatestandards t!at!el) maintaincleanin 7lu0rication#it! minimal

time effort.# Im)rove

efficiency ofc!ec1in 0yvisualcontrols.

# /ustain 0asicconditions *)revent forceddeterioration.

# Perform accuratec!ec1in 0y visual

controls.

# Ensureo)eratorsres)ectstandards.

# Encouraeteam#or1 0y

ma1ina#areness ofindividual roles.

# 4el) in #ritin,cleanin andlu0ricatinstandards.

# ive tec!nicalassistance in

ma1instandards.

# 4el) in settinvisual controls.

Contd.

% l *l i * ki d



B0!"#$%%&'! %() *resentation in +*-+*4

%ample *leaning, *ecking andu0rication %tandard

T!e /even /te)s to A M3



B0!"#$%%&'! %() *resentation in +*-+*"


/te)%= Activities 4ard#are oals /oft#are oals 6ole ofManaers 7 /taff

Conductenerale+ui)mentins)ection

# Provideins)ections1ills trainin0ased onmanuals.

# Im)rove

)erformance 0yeneralins)ection ofe+ui)ment.

# Modifye+ui)ment tofacilitateins)ection andvisual controls.

# Im)rovement inrelia0ility 0yins)ection andreversal ofdeterioration.

# Im)rove ins)ection

relia0ility 0y visualcontrols suc! asname)lates, > ?elts)ecificationdis)lay, correcto)eratin rane onaues.

# Learne+ui)mentdetails, desinfunctionst!rou! !andson ins)ection.

# Learn to attac1a0normalities.

# @se relayteac!in.

# Peo)leunderstand touse data.

# Pre)areins)ection *trou0le s!ootinmanuals.

# $ra# ins)ectionsc!edule.

# ive sim)letrainin onmet!ods ofeliminatina0normalities.

# ive uidance inim)rovin visual

controls.

Contd.




B0!"#$%%&'! %() *resentation in +*-+*10


/te)%5 Activities 4ard#areoals

/oft#are oals 6ole ofManaers 7 /taff

Esta0lis!standards* )erform)rocessins)ection

# Provideinstruction in)rocess)erformance,o)eration andad;ustment to

im)roveo)erationalrelia0ility.

# Incor)oratecleanin andins)ectionstandards foreac!

e+ui)ment.

# Im)rove )rocesssta0ility t!rou!correcto)eration.

# Im)rove )rocessins)ection 0y

visual controls.# Modify

e+ui)ment toma1e it easy touse.

# Ena0le o)eratorsto o)erate)rocesses anddeal #it!a0normalities andrectify.

# Ena0le o)eratorsto understand =Mrelations!i) and+uality.

# Ena0le o)eratorson role ofAutonomousMaintenance *o#ners!i).

# Pre)are )rocessand ins)ectionmanuals.

# Pre)are trou0les!ootinmanuals.

# Pre)areins)ectionmanuals.

# Pre)are)reventivemaintenancemanuals.

Contd.




B0!"#$%%&'! %() *resentation in +*-+*1!

T!e /even /te)s to A.M

/te)%( Activities 4ard#areoals

/oft#are oals 6ole ofManaers 7

/taff /ystematise

Autonomousmaintenance

# Ac!ieveQualityMaintenance0y clear)rocedures* standards

for AM.# Im)rove set

u) met!ods.

# 6educe -IP

# Esta0lis!/elfManaement

for#or1)laceflo#.

# Esta0lis!relation 0et#eenQuality * E+)t.

# 6evie# *im)rove )lantlayout.

# /tandardisemaintenances)ares, tools,-IP, layout etc.

# Introduce visualcontrols.

# E8)and s)!ere ofself manaement.

# 4el) understandrelations!i) inQuality * E+)t.

# ?y standardisation

start #or1)lace *)rocessim)rovements.

# 6aise level of#or1ers andsu)ervisorsres)onsi0ility.

# Pre)are systemflo# diaramsfor )rocessesandstandardise.

# Pre)are +uality

maintenancemanuals.

# Train on IEPManual, QCtec!ni+ues.

Contd.




B0!"#$%%&'! %() *resentation in +*-+*1/

T!e /even /te)s to A.M

/te)% Activities 4ard#are oals /oft#are oals 6ole ofManaers 7

/taff Im)lement

full AM# Institutionalise

Im)rovementsandstandardisation.

# Analyse MT?F toim)rove EE.

# Analyse data toIm)rove EE,6elia0ility,/afety, QualityandMaintaina0lity.

# Increasea#areness ono0;ectives andcosts.

# )erators develo)re)air s1ills.

# )erators analysedata.

# Train on M?.

# ive !ands ons1ill trainin.

# ive tec!nicaltrainin.

Contd.

autonomous maint trg

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