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1© Operational Excellence Consulting. All rights reserved. 1
Autonomous
Maintenance
© Operational Excellence Consulting. A...
© Operational Excellence Consulting. All rights reserved. 2
Learning Objectives
1. Understand the key concepts of TPM and ...
© Operational Excellence Consulting. All rights reserved. 3
Contents
1. Overview of TPM
2. Introduction to AM
3. Tools of ...
4© Operational Excellence Consulting. All rights reserved. 4
Machine failures have many hidden causes
Failure
Loosening
Co...
5© Operational Excellence Consulting. All rights reserved. 5
Eight Pillars of TPM
TPMintheOffice
Safety,Health&Environment...
© Operational Excellence Consulting. All rights reserved. 6
What is Autonomous Maintenance?
 Autonomous Maintenance is ma...
© Operational Excellence Consulting. All rights reserved. 7
What AM Is NOT
 An activity to keep operators busy when produ...
8© Operational Excellence Consulting. All rights reserved. 8
AM is a Paradigm Shift
Old Attitude TPM Attitude
I use I main...
© Operational Excellence Consulting. All rights reserved. 9
AM Supports a Culture Change
Work Systems
& Processes
Behavior...
© Operational Excellence Consulting. All rights reserved. 10
AM Activities Improve Equipment
Efficiency & Upgrade Operator...
11© Operational Excellence Consulting. All rights reserved. 11
Goals of Autonomous Maintenance
Goals of
Autonomous
Mainten...
12© Operational Excellence Consulting. All rights reserved. 12
4
3
Set Optimum
Equipment Conditions
2
1
Correct & Restore
...
© Operational Excellence Consulting. All rights reserved. 13
Autonomous Maintenance Approach
Source: Adapted from Society ...
© Operational Excellence Consulting. All rights reserved. 14
3 Key Tools for AM Team Activities
Activity
Boards
Meetings
O...
15© Operational Excellence Consulting. All rights reserved. 15
Activity Board & Daily Standup Meetings
Agenda
• Yesterday’...
16© Operational Excellence Consulting. All rights reserved. 16
Types of One-Point Lessons
1. Basic Knowledge
Lesson
2. Exa...
© Operational Excellence Consulting. All rights reserved. 17
Examples of One-Point Lesson
One point labels
One-point lesso...
© Operational Excellence Consulting. All rights reserved. 18
7 Steps of Autonomous Maintenance
Steps of AM Main Objective
...
© Operational Excellence Consulting. All rights reserved. 19
Step 1 – Clean and Inspect
 Eliminate all dirt and grime on ...
20© Operational Excellence Consulting. All rights reserved. 20
JOB BREAKDOWN SHEET
Operation :
Parts :
Tools & Materials :...
© Operational Excellence Consulting. All rights reserved. 21
Example of Tagging
During initial cleaning
Afterwards –
Every...
© Operational Excellence Consulting. All rights reserved. 22
Monitoring Tags
0
50
100
150
200
250
July
A
ugustSeptem
ber
O...
© Operational Excellence Consulting. All rights reserved. 23
When You Find a Problem, Tag It!
 Attach a tag to each
probl...
© Operational Excellence Consulting. All rights reserved. 24
Step 2 – Eliminate Problem Sources and
Inaccessible Areas
 C...
© Operational Excellence Consulting. All rights reserved. 25
Step 3 – Draw up Cleaning and
Lubricating Standards
 Develop...
© Operational Excellence Consulting. All rights reserved. 26
Step 3 – Draw up Cleaning and
Lubricating Standards
 How to ...
27© Operational Excellence Consulting. All rights reserved. 27
5W & 1H
Who
3
What
2
Why
1
When
4
Where
5
How
6
© Operational Excellence Consulting. All rights reserved. 28
Dept. / Line : Bldg Y Mach. ID : Date: 4/28/2004
S D W M
Clea...
© Operational Excellence Consulting. All rights reserved. 29
Step 4 – Conduct General Inspections
The Visual Workplace
Sou...
30© Operational Excellence Consulting. All rights reserved. 30
Example: General Inspection
Abnormal hydraulic pump
sound/t...
31© Operational Excellence Consulting. All rights reserved. 31
Checklist for Daily Operator PM
 1. Check coolant level th...
© Operational Excellence Consulting. All rights reserved. 32
Maintenance
Activities
Breakdown
Maintenance
Predictive
Maint...
© Operational Excellence Consulting. All rights reserved. 33
Visual Control Example: Lubrication
Mark lubrication points
w...
© Operational Excellence Consulting. All rights reserved. 34
Ideas for Visual Control
 “Inspected” marks and match
marks
...
© Operational Excellence Consulting. All rights reserved. 35
Three Important Reasons for Audits
1. To determine whether ea...
© Operational Excellence Consulting. All rights reserved. 36
Key Implementation Points of AM
1. Proper education and train...
© Operational Excellence Consulting. All rights reserved. 37
How to Sustain AM?
 Active leadership for TPM initiative
 A...
© Operational Excellence Consulting. All rights reserved.
About
Operational Excellence
Consulting
© Operational Excellence Consulting. All rights reserved. 39
About Operational Excellence
Consulting
 Operational Excelle...
© Operational Excellence Consulting. All rights reserved.
To download this presentation,
please visit us at:
www.oeconsult...
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Autonomous Maintenance (Jishu Hozen) by Operational Excellence Consulting

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Autonomous Maintenance refers to TPM activities that involve operators in maintaining their own equipment, independent of the maintenance department. Activities in an AM program include: daily inspections, lubrication, parts replacement, simple repairs, abnormality detection and precision checks. The goals of the program are to prevent equipment deterioration, restore equipment to its ideal state, and establish basic conditions needed to keep equipment well maintained. AM is one of the most important building blocks in any TPM program.

Learning Objectives​

1. Understand the key concepts of TPM and Autonomous Maintenance activities
2. Learn how to implement the Autonomous Maintenance activities, step by step
3. Learn how to use activity boards, meetings and one-point lessons to promote TPM goals
4. Understand the critical success factors in sustaining Autonomous Maintenance activities on the shopfloor

Contents​

1. Overview of TPM
2. Introduction to AM
3. Tools of AM
4. How to Implement the Seven Steps of AM: The Step by Step Approach
5. Sustaining AM

To download this complete presentation, please visit: http://www.oeconsulting.com.sg

Published in: Business, Technology

Autonomous Maintenance (Jishu Hozen) by Operational Excellence Consulting

  1. 1. 1© Operational Excellence Consulting. All rights reserved. 1 Autonomous Maintenance © Operational Excellence Consulting. All rights reserved.
  2. 2. © Operational Excellence Consulting. All rights reserved. 2 Learning Objectives 1. Understand the key concepts of TPM and AM activities 2. Learn how to implement the AM activities, step by step 3. Learn how to use activity boards, meetings and one- point lessons to promote TPM goals 4. Learn how to measure and audit AM activities and performance 5. Familiarize with the JIPM TPM excellence criteria for AM 6. Understand the critical success factors in sustaining AM activities on the shopfloor
  3. 3. © Operational Excellence Consulting. All rights reserved. 3 Contents 1. Overview of TPM 2. Introduction to AM 3. Tools of AM 4. How to Implement the Seven Steps of AM: The Step by Step Approach 5. Measuring & Auditing AM Activities 6. JIPM TPM Excellence Criteria for AM 7. Sustaining AM NOTE: As this is a PREVIEW, only selected slides are shown. To download the complete presentation, please visit: http://www.oeconsulting.com.sg
  4. 4. 4© Operational Excellence Consulting. All rights reserved. 4 Machine failures have many hidden causes Failure Loosening Contamination CorrosionLeaks FlawsDeformation VibrationCracks Backlash Improper Temperature Wear Less Visible Visible Failure is what we see but is only the tip of the iceberg Minor machine defects are generally unnoticed but are the cause of almost all machine failures
  5. 5. 5© Operational Excellence Consulting. All rights reserved. 5 Eight Pillars of TPM TPMintheOffice Safety,Health&Environment AutonomousMaintenance PlannedMaintenance FocusedImprovement EarlyEquipment Management QualityMaintenance Education&Training 5S & Visual Management TPM Goals: Zero Defects, Zero Breakdowns, Zero Accidents
  6. 6. © Operational Excellence Consulting. All rights reserved. 6 What is Autonomous Maintenance?  Autonomous Maintenance is maintenance performed by operators  Basic maintenance that can be easily performed on a daily basis, e.g. inspection, cleaning, lubrication, etc.  Learning about the equipment to understand how it works and be able to spot signs of trouble  An employee engagement program as part of the Lean/TPM initiative
  7. 7. © Operational Excellence Consulting. All rights reserved. 7 What AM Is NOT  An activity to keep operators busy when product demand is low  Doing a favor for Maintenance department  Performing basic maintenance without a purpose  Making operators into skilled tradesman
  8. 8. 8© Operational Excellence Consulting. All rights reserved. 8 AM is a Paradigm Shift Old Attitude TPM Attitude I use I maintain & I fix We maintain Maintenance Operator MaintenanceOperator
  9. 9. © Operational Excellence Consulting. All rights reserved. 9 AM Supports a Culture Change Work Systems & Processes Behavior Attitude Culture Changes the way we act… And the way we think… By improving equipment and processes…
  10. 10. © Operational Excellence Consulting. All rights reserved. 10 AM Activities Improve Equipment Efficiency & Upgrade Operator Skills Correction & Restoration Traditional Culture Operator’s Knowledge Detect Abnormalities Cleaning is Inspection Visual Workplace Learn Equipment Structure & Function TPM/Lean Culture Autonomous Maintenance Equipment Maintenance Skills Maintain Optimum Equipment Conditions Standards & Inspection Autonomous Management Equipment- focused Operator- focused
  11. 11. 11© Operational Excellence Consulting. All rights reserved. 11 Goals of Autonomous Maintenance Goals of Autonomous Maintenance Prevent Equipment Deterioration Equipment Restoration & Proper Management Establish Basic Conditions
  12. 12. 12© Operational Excellence Consulting. All rights reserved. 12 4 3 Set Optimum Equipment Conditions 2 1 Correct & Restore Abnormalities Detect Abnormalities Four Equipment-related Skills for Operators Maintain Optimum Equipment Conditions
  13. 13. © Operational Excellence Consulting. All rights reserved. 13 Autonomous Maintenance Approach Source: Adapted from Society for Maintenance & Reliability Professionals Check ActPlan Do Examine & expose problems Counter & solve problems Execute & follow standards & rules Prevent recurrence through improvement
  14. 14. © Operational Excellence Consulting. All rights reserved. 14 3 Key Tools for AM Team Activities Activity Boards Meetings One-Point Lessons
  15. 15. 15© Operational Excellence Consulting. All rights reserved. 15 Activity Board & Daily Standup Meetings Agenda • Yesterday’s issues • Lessons learned • Manpower status • Update from top management • Lean/TPM activities • Today’s target & actions
  16. 16. 16© Operational Excellence Consulting. All rights reserved. 16 Types of One-Point Lessons 1. Basic Knowledge Lesson 2. Examples of Problems 3. Examples of Improvement • Training tool designed to fill in knowledge gaps • To ensure team members have consistent knowledge they need for daily production and TPM activities • Lessons are focused on equipment subsystems, safety points, or basic operating information • Based on problems that have already occurred, these lessons are designed to communicate knowledge or skills to help operators prevent similar problems from happening in the future • To ensure that successful improvement ideas are used widely, these lessons present what needs to be done to prevent or correct equipment abnormalities • It describes the approaches, actions, and results of specific improvement projects
  17. 17. © Operational Excellence Consulting. All rights reserved. 17 Examples of One-Point Lesson One point labels One-point lessons are typically depicted as standard letter size documents. However, they are even more effective the critical information is condensed onto a label or set of labels. The information can then be posted right at the point of need – exactly where your employees can benefit from it. One-point lessons If employees are struggling to remember one step in a procedure, consider creating a “one point” or “single point” lesson. A one-point lesson is different from a typical procedure in that it focuses on one critical point. Source: Brady 50 Lean Visuals Pocketbook
  18. 18. © Operational Excellence Consulting. All rights reserved. 18 7 Steps of Autonomous Maintenance Steps of AM Main Objective 1. Clean and inspect To keep the state of the equipment from deteriorating 2. Eliminate problem sources and inaccessible areas 3. Draw up cleaning and lubricating standards 4. Conduct general inspections General inspection standards to complement the first 3 steps 5. Conduct autonomous inspections 6. Standardize through visual workplace management Focus on the entire work area 7. Implement autonomous equipment management Independent maintenance activities as part of business as usual
  19. 19. © Operational Excellence Consulting. All rights reserved. 19 Step 1 – Clean and Inspect  Eliminate all dirt and grime on the machine, lubricate and tighten bolts  Find and correct problems  Implement the Activity Board and the 4Ms  Address operators’ questions during education process  Develop countermeasures to mis-operations as early as possible Eliminate all sources of dirt and grime on the machine, lubricate, tighten bolts, and find and correct problems
  20. 20. 20© Operational Excellence Consulting. All rights reserved. 20 JOB BREAKDOWN SHEET Operation : Parts : Tools & Materials : Safety Equipment : MAJOR STEPS KEY POINTS REASONS What: A logical segment of the operation when something happens to advance the work How: Anything in a step that might — 1. Make or break the job 2. Injure the worker 3. Make the work easier Why: Reasons for the key points 1. 2. 3. 4. Step 1 – Clean and Inspect Each key point can be translated into One-point lessons
  21. 21. © Operational Excellence Consulting. All rights reserved. 21 Example of Tagging During initial cleaning Afterwards – Everyday process Tag is removed only after the repair is made
  22. 22. © Operational Excellence Consulting. All rights reserved. 22 Monitoring Tags 0 50 100 150 200 250 July A ugustSeptem ber O ctober N ovom ber D ecem ber NumberofTags Tags Issued Tags Restored
  23. 23. © Operational Excellence Consulting. All rights reserved. 23 When You Find a Problem, Tag It!  Attach a tag to each problem you expose so that it won’t be forgotten  Fix problems as soon as possible and remove the tag  Draw up plans for resolving problems that can’t be addressed immediately
  24. 24. © Operational Excellence Consulting. All rights reserved. 24 Step 2 – Eliminate Problem Sources and Inaccessible Areas  Correct sources of dirt and grime  Prevent spattering  Improve accessibility for cleaning and lubrication  Establish time targets for cleaning  Establish tentative standards Correct sources of dirt and grime; prevent spattering and improve accessibility for cleaning and lubrication. Shorten the time it takes to clean and lubricate.
  25. 25. © Operational Excellence Consulting. All rights reserved. 25 Step 3 – Draw up Cleaning and Lubricating Standards  Develop periodic schedule and follow it strictly  Schedule should cover: - Cleaning - Inspection - Lubrication - When, what and how Write standards that will ensure that cleaning, lubricating, and tightening can be done efficiently (Make a schedule for periodic tasks) Use TWI Job Instruction Job Breakdown Sheet: - Major steps - Key points - Reasons for key points
  26. 26. © Operational Excellence Consulting. All rights reserved. 26 Step 3 – Draw up Cleaning and Lubricating Standards  How to Develop Step 3 - Maintain the cleanliness achieved in Step 2 - Cumulative improvements - Divide a step into sub-steps
  27. 27. 27© Operational Excellence Consulting. All rights reserved. 27 5W & 1H Who 3 What 2 Why 1 When 4 Where 5 How 6
  28. 28. © Operational Excellence Consulting. All rights reserved. 28 Dept. / Line : Bldg Y Mach. ID : Date: 4/28/2004 S D W M Cleaning 1 Water trap Empty bowl Open valve Cloth 1 X Operator This is the maximum level for water in the bowl. Open valve at bottom to release water, wipe up with clean cloth. Insert Picture Here Tools T (Min) Person Resp. Autonomous Maintenance Routine Cleaning, Inspection, & Lubrication Standard Freq Diagram No. Item Criterion Method Area : Bag Printer Tag # : Example: Establish Cleaning Standard
  29. 29. © Operational Excellence Consulting. All rights reserved. 29 Step 4 – Conduct General Inspections The Visual Workplace Source: Practical TPM by James Leflar
  30. 30. 30© Operational Excellence Consulting. All rights reserved. 30 Example: General Inspection Abnormal hydraulic pump sound/temperature can mean cavitation, pump failure, etc. Inspection Stickers See something wrong? Smell something? Feel something wrong? Hear something wrong? Source: Nippon Denso
  31. 31. 31© Operational Excellence Consulting. All rights reserved. 31 Checklist for Daily Operator PM  1. Check coolant level through clear Plexiglas  2. Check heat exchanger fans (strings should be moving)  3. Check servo drive fans (string should be moving)  4. Check heat exchanger air filter (change when dark)  5. Check servo drive air filter (change when dark)  6. Check way lube reservoir (add when low)  7. Check main motor air filter (change when dark)  8. Check main motor cooling fan (string should move)  9. Check mist collector motor and air filter (change when dark)  10. Check bar feeder hydraulic motor air filter  11. Check bar feeder hydraulic oil level (add when low) Example: Checklist for Autonomous Inspections
  32. 32. © Operational Excellence Consulting. All rights reserved. 32 Maintenance Activities Breakdown Maintenance Predictive Maintenance Preventive Maintenance Routine Maintenance ROBUSTNESS IMPROVEMENT EFFECTIVE AND APPROPRIATE REPAIRS TRENDS MEASUREMENT AND CONTROL CONDITION BASED SERVICING BUILDING OF PROGRAMS TIME BASED APPLICATIONS CLEANING - REFURBISHING LUBRICATION & TIGHTENING DAILY INSPECTION DAILY EQUIPMENT CARE X X X X X X X X X X X Production Maintenance Example: AM – Who Does What?
  33. 33. © Operational Excellence Consulting. All rights reserved. 33 Visual Control Example: Lubrication Mark lubrication points with a label that identifies the proper grease quantity and frequency. To ensure that the correct lubricant is used, consider also color coding the lube point label to match the label on the appropriate grease gun. Source: Brady 50 Lean Visuals Pocketbook
  34. 34. © Operational Excellence Consulting. All rights reserved. 34 Ideas for Visual Control  “Inspected” marks and match marks  Color-coding (blue) on bolts reserved for adjustment by maintenance personnel only  Color-coding (yellow) on holes that do not require bolts Equipment Elements
  35. 35. © Operational Excellence Consulting. All rights reserved. 35 Three Important Reasons for Audits 1. To determine whether each step has been fully implemented 2. To provide feedback to teams on the strengths and weaknesses of their activities 3. To clarify what needs to be achieved and how best to achieve it
  36. 36. © Operational Excellence Consulting. All rights reserved. 36 Key Implementation Points of AM 1. Proper education and training a. Are the operators certified? b. Who certifies them? 2. Development of four equipment-related skills 3. Establishment of AM schedule for each operator 4. Autonomous management using activity board and meeting 5. Identifying and reporting problems 6. Participation in problem solving and OEE improvement
  37. 37. © Operational Excellence Consulting. All rights reserved. 37 How to Sustain AM?  Active leadership for TPM initiative  AM is owned by Production department and supported by Maintenance department  Proper operator training, education and skills certification  The time required for cleaning and lubrication must be included in the daily schedule  Supervisors need to ensure that AM activities are performed
  38. 38. © Operational Excellence Consulting. All rights reserved. About Operational Excellence Consulting
  39. 39. © Operational Excellence Consulting. All rights reserved. 39 About Operational Excellence Consulting  Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness.  One of our unique strengths is going beyond a tools-focused approach to seamlessly integrate people, processes, technology and continuous improvement initiatives to suit the specific needs and situations of our clients.  We provide corporate learning programs and management advisory services to assist our clients to achieve breakthrough in business performance and effectiveness. Our aim is to support our clients in designing, managing and executing lasting beneficial change.
  40. 40. © Operational Excellence Consulting. All rights reserved. To download this presentation, please visit us at: www.oeconsulting.com.sg END OF PREVIEW

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