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Autonomous Maintenance

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Assisting Operations to maintain its own equipment …

Assisting Operations to maintain its own equipment

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Transcript

  • 1. Autonomous Maintenance
    Assisting the Operations to maintain its own equipment
    Anand Subramaniam
  • 2. 2
    “Automatic simply means that you can't repair it yourself.”
    - Mary H. Waldrip
  • 3. 3
    Highlights
    Maintenance Types
    Autonomous Maintenance
  • 4. Maintenance Types
  • 5. Maintenance Strategy & Tactics
    5
    Business Objectives & Strategy
    Production Objectives & Strategy
    Plant & Equipment
    • Asset register
    • 6. Classification
    • 7. Criticality
    • 8. Operating Regimes
    Maintenance Objectives
    Maintenance Policy
    Mnt – Strategy & Tactics
    • Prevention : Reliability : Planned
    Information
    Resources
    Procedures
    Organisation
    Control system
  • Types
    6
    Reliability
    Planned
    Prevention
  • 26. Meantime to Failure
    (Goal - Maximise)
    • Machine Breakdown
    • 27. Tool Breakdown
    • 28. Part Failure
    Meantime to Repair
    (Goal - Minimise)
    • Diagnose problem
    • 29. Correct problem
    • 30. Set up Machine to make good parts
    • 31. Spare parts control
    Analyse
    (Statistical Tools)
    • Reliability Measures
    • 32. Problem Solving Tools
    • 33. Vibration Analysis Tools
    Reliability Maintenance
  • 34. Reliability and Maintenance
    8
    Strategies
    Tactics
    • Reliability
    • 42. Provide redundancy
    • 43. Improve individual components
    • 44. Maintenance
    • 45. Increase repair capabilities
    • 46. Implement preventive maintenance
  • Planned Maintenance
    Maintenance department primarily responsible
    Re-adjustment of Machines to bring back to original state
    Feedback information to Maintenance Prevention Group
    Collection of Reliability Data
    MTBF
    MTTR
    Finding and coping with chronic defects
    Machine accuracy control (calibration)
    Schedule boards (Visual Management)
    Control of Spare Parts
    9
  • 47. Planned Maintenance Transition
    10
  • 48. Maintenance Prevention
    Life Cycle Costing
    Assembly at Supplier
    Input from Kaizen activities
    Input from Reliability Maintenance
    Input from Preventative Maintenance
    Design reviews (Operators, Supervisors, Engineers)
    Final Inspection at Supplier
    Maintenance and Operations Manual preparation
    Safety Issues visible, aware and worked
    Preventative Maintenance Schedule posted, adhered to
    New equipment design integrated with New Product Introduction (NPI) efforts
    11
  • 49. Autonomous Maintenance
  • 50. Definition
    Operations maintains its own equipment
    Utilise 7-step plan*
    (*Source: Japan Institute of Plant Maintenance - JIPM)
    13
  • 51. Seven Steps to TPM
    14
    Autonomous Management
    7
    6
    5
    4
    3
    2
    1
    Aut. Mgt.
    7
    Orderliness & Tidiness
    6
    Autonomous Cleanup
    5
    Overall Checkup (Internal)
    4
    Initial Standards Formulation
    3
    Stop Sources of defects (External)
    2
    Starts with 6S
    Initial Clean-up (External)
    1
  • 52. Step 1 – Initial Clean-up (External)
    Kick-off” program
    Closely aligned with 6S (5S + 1)
    Management and Staff show commitment
    Clean, Sand and Paint
    Identify sources of defects
    Gauge hidden
    Limit switch buried in debris
    Crack in Housing
    15
  • 53. Step 2 – Stop Sources of Defects (External)
    Ask ‘why ?’ five times
    Replace parts with cracks or worn seals
    Teach Operators how to modify equipment
    Conduct Set-up Workshops & Practice
    Modify Equipment for easier checking and to eliminate sources for debris and contamination
    Guards
    Chip removal
    Acrylic covers to see V - belts and moving parts
    16
  • 54. Step 3 – Initial Standards Formulation
    Standards for clean-up and checking
    What equipment should be cleaned and checked?
    What points should be checked?
    Who should check?
    What check sheet should be used?
    How to react to changes.
    Standards are to capture what has been learned in steps 1 and 2
    17
  • 55. Step 4 – Overall Checkup (Internal)
    Leaders (1st line Supervisors) trained
    Hydraulics
    Air Pressure
    Electrical/ Electronics
    Lubrication
    Mechanical
    One point lessons developed (Visual Management)
    Team up Engineers, Maintenance, and Operators
    Tear down equipment
    Analyse defects
    Present findings
    18
  • 56. Step 5 – Autonomous Checkup
    Develop Standards for routine internal checkup
    Hydraulics
    Air Pressure
    Electrical/ Electronics
    Lubrication
    Mechanical
    Operator executes routine checks
    19
  • 57. Step 6 – Orderliness and Tidiness
    Improve on Supplier Activity
    Spare parts supply partners
    Spare parts stores
    Spare parts inventory
    Improve on Tool Activity
    Tool Crib orderliness
    Tools frequently used at work station
    (refer to Visual Management / Visual Control)
    20
  • 58. Step 7 – Autonomous Management
    Process never ends
    Metrics
    Audits
    Each process post Results (actual) against Goal (target)
    Zero lost time accidents
    Zero Defects
    Zero Breakdowns
    Zero set-up time or at least < 10 minutes
    21
  • 59. 22
    “The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at or repair.”
    - Douglas Adams
  • 60. 23
    Good Luck
    http://www.linkedin.com/in/anandsubramaniam