HOW PREPARE THE 4 STEP IN AUTONOMUS MAINTENANCE - TPM PILLAR - Three schematic routes for its construction and execution.

1. HOW PREPARE THE 4
STEP IN AUTONOMUS
MAINTENANCE
- TPM PILLAR -
Three schematic routes for its
construction and execution
The successfully sinergy between pillars Planned
Maintenance, Education and Training for this
construction and execution

2. PRIORITIZING PROBLEMS
(Mode-Fault-Component Matrix,
Map of abnormalities y criticality
of equipment)
Pillars Manteniance and Training
BUILD SUPPORT MATERIAL
FOR EACH TOPIC
(Documents, prototypes, etc.)
PLANNING MANTENIANCE
DEFINES TRAINING TARGETS
GOALS TO OBTEIN AT END OF STEP:
- Failures decreases by 90%
- Quality defects decreases by 50% (QA matrix) {a}
- Quality claims decreases by 20% to 30% {a}
- Zero Accidents
- Increased abnormalities card generation (Red and blue)
- Elimination of dirt and local sources difficult to access -> Continuos
improvement cycle
- Standars upgrade -> Continuos improvement cycle
CRITERIA FOR SELECTING OPERATIONS TO TRANSFER TO
OPERATORS:
- They are covered in the training
- No special tools required
- No need additional safety skills
- Not required major equipment disarms
Consider w hether additional know ledge is needed outside of training, to
program according to curriculum development
PM, but with leading and supporting by
Training in pedagogical criteria
BASIC SCHEMA FOR ACTIVITIES FOR 4 AM'S STEP
PILLARS OF SAFETY, QUALITY
..., REVIEW SUPPORT
MATERIALS THAT
INSTRUCTORS WILL USE IN
TRAININGS
EVERYTHINGS
RIGHT?
SET ACCORDING TO
COMMENTS A
SUGGESTIONS
No
PILOT TRAINING BEFORE
MAKING DIRECT TO
COORDINATORS AND/OR
TEAM LEADERS (Validation of
training method)
EVERYTHINGS
RIGHT?
No
Yes
Yes
CYCLE TRAINING PROCESS EXECUTION, MONITORING
AND AUDIT A OPERATION IN EACH SUBJECT
Theoretical and practical training
Monitoring knowledge and skills taught (in the
workplace and through the Four Steps Method)
Internal audits: Workgroup and his coordinators
(team leaders)
Pillars Audit coordinators and workgroup
EVERYTHINGS
RIGHT?
No
Yes
SET ACCORDING TO
COMMENTS A
SUGGESTIONS
CONTINUE TO
NEXT LEVEL
AUDIT FINAL STEP
KEY DELIVERABLES IN EACH SUBJECT:
- Abnormalities identified and managed by team members
- Sources of pollution and Hard to Reach Places eliminated.
- Updated Standards
- OLP assigned
- Hidden risks identified and controlled
- Others as the subject and the need of the area
1
2
3
{a} Only suggest values. It's necessary check
the historic quality data at begining step, for
set goals to real situation in line or area.
Repeat
this
cycle
CreatedbyEduardoTrujilloHernández-2013

3. DEFINITION AND
PRIORITIZING OF
SUBJECTS
Definition of subjects
List of interventions to transfer from PM to AM
Complete?
No
CONSTRUCTION/
REVISION OF
TRAINING MATERIAL
Yes
Revision of material and available documents
Prototypes, Models
OPL
Videos
Handbooks, books
Instructor´s plan
Basic analysis, CAP-Do, etc.
Powerpoint presentations
(OPTIONAL)
Complete?
No
Yes
EXECUTE PILOTS OF
EACH SUBJECT
PRESENTATION OF
TRAINING PLAN
Yes
Cronogram
List of interventions to transfer
General Plan of training in workplace (OJT)
Complete?
No
Yes
EXECUTION OF
PLAN
GUIDE TO PREPARING AND CHECKING
TRAINING IN 4 STEP IN AM'S
Area/Line coordinators,
team leaders
This activity can be after presentation of the
training plan:
Pillars (Led by Training pillar), area or line
coordinators, plant manager...
CreatedbyEduardoTrujilloHernández-2013

4. THIS METHOD IS TEACHED BY TRAINING PILLAR THROUGH SOME EXERCISES THAT
ENSURE IN INSTRUCTORS ITS KNOWLEDGE AND APLICATION WHEN THEY ARE
TEACHING OTHERS.
FOR THE PLANS CONSTRUCTION, THE TRAINING PILLAR TEACHS ABOUT ITS
CONSTRUCTION, AND BESIDES REVIEW THEM INCLUDING THE OLP, STANDARDS
AND OTHER DOCUMENTS THAT WILL BE USED IN THE TRAINING MOMENTS WITH
LEARNERS.
APPLY THE TRAINING
USING THE "FOUR STEPS
METHOD" (OJT)
SUPPORTING AND
CORRECTING IN THE
WORKPLACE
EVERYTHING ARE
ACCORDING WITH
CONDITIONS?
LAST MONITORING IN
WORKPLACE
CERTIFICATE THE NEW
SKILL
UPGRADE THE
COMPETENCES/SKILLS
MATRIX
Yes
NO
PROCEDURE TO TRAINING IN COMPETENCES AND SKILLS
PLANNING ABOUT POINT
OR ACTIVITY TO TRAIN
"FOUR STEPS METHOD TO TRAINING" (OJT METHOD):
1. DIAGNOSE / MOTIVATE AND THEN SHOW : INSTRUCTOR QUESTIONS , INQUIRES AND
MOTIVATES THE LEARNER ABOUT NEW KNOWLEDGE AND SKILLS. DEMONSTRATE AND
EXPLAIN DONE SIMULTANEOUSLY . THE LEARNER PAY ATTENTION .
2. TRY: THE INSTRUSTOR ASKS THE LEARNER TO EXPLAIN AND HE DOES AS
INSTRUCTED .
3. TEST: HERE THE LEARNER EXPLAINS AND DOING THE PROCEDURE FOLLOWING
SECURITY NORMS TO AVOID FAILURES , ACCIDENTS AND QUALITY PROBLEMS .
4. MONITORING . THE INSTRUCTOR AND LEARNER AGREE ABOUT DOING SOME
EXERCISES SIMILAR TO 4 STEP OF THIS METHOD , UNTIL THE KNOWLEDGE AND SKILL
ARE FIXED IN THE OPERATOR . THIS STEP ENSURES THAT THE SKILL IS ACQUIRED .
ATTENTION: IN EVERY MOMENT , THE INSTRUCTOR CORRECTED WHEN NECESSARY .
POINTS TO CONSIDER IN THESE PLANS:
WHAT TOOLS ARE NECESSARY ?
OLPAND/OR STANDARS CAN USE DURING THE TRAINING .
ARE NECESSARY SOME SECURITY PERMISSIONS ?
ARE THERE HEALTH RESTRICTIONS ?
HOW LONG WOULD TAKE THE TRAINING ?
THE NEW ACTIVITIES
LEARNED NOW ARE
RESPONSABILITY OF
OPERATORS (AM)
CreatedbyEduardoTrujilloHernández-2013