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Autonomous Maintenance

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Assisting Operations to maintain its own equipment

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Autonomous Maintenance

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

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