Hofincons - TPM Pillar 1 - Autonomous Maintenance (1).pdf

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TPM Pillar 1 –
Autonomous Maintenance

• Don’t note things down, try to understand
• Actively participate when encouraged, try to make this a dialogue rather than a
monologue
• If you have a questions, write your questions in the chat area during the
presentation, these will be answered at the end
• Question breaks will be taken appropriately
• Mute your line if you are not speaking & remember to mute again when you have
spoken
Ground rules for the webinar participation

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. Understand the critical success factors in sustaining AM activities on the shop floor
Objectives

Machine failure may have many hidden causes

Pillars of TPM
It is defined as a maintenance strategy where machine operators continuously monitor their
equipment, make adjustments and perform minor maintenance tasks on their machines. ...

• Autonomous maintenance is the first pillar in the total productive maintenance strategy.
• 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
What is Autonomous Maintenance?

• 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
What this pillar is NOT…

AM is a Paradigm Shift

AM Supports a Culture Change

Goals of Autonomous Maintenance

AM Activities Improve Equipment Efficiency & Upgrade Operator Skills

Equipment related skills that operators acquire through AM

3 Key tools for AM Team Activities

Activity Board

Daily Standup Meetings

Types of One-Point Lessons

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.
One point labels
One-point lessons are typically depicted as standard
letter size documents. However, they are even more
effective is that 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.
Examples of One-Point Lesson

7 Steps of Autonomous Maintenance
Steps of AM Objective fulfilled
1. Clean & 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

• Train operators on the concepts of AM
• Address operators' questions during training process
• Eliminate all dirt and grime on the machine, lubricate and tighten bolts
• Find and correct problems
• Implement the Activity Board
• Develop counter measures for possibility of wrong operations as early as possible
1
9
Step 1 - Clean and Inspect

• 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
When You Find a Problem, Tag It!

During initial cleaning Afterwards - Everyday process
Tag is removed only after the
repair is made
Example of Tagging

Monitoring Tags

Step 1- Clean and Inspect

• Correct sources of dirt and grime
• Prevent spattering
• Improve accessibility for cleaning and lubrication
• Establish time targets for cleaning
• Establish tentative standards before standards are finalised
Step 2 - Eliminate Problem Sources and Inaccessible Areas

- Cleaning
- Inspection
- Lubrication
- Tightening
- When, what and how
Use Job Instruction
Job Breakdown Sheet:
- Major steps
- Key points
- Reasons for key points
Step 3 - Draw up Cleaning and Lubricating Standards
• Develop periodic schedule and follow it strictly
• Schedule should cover:

How to Develop Step 3
• Maintain the cleanliness achieved in Step 2
• Cumulative improvements for achieving best results
• Divide a step into sub-steps
Step 3 - Draw up Cleaning and Lubricating Standards

Answering 5W & 1H

Example: Establish Cleaning Standard

Step 4 - Conduct General Inspections

Step 5 - Checklist for Autonomous Inspections

Step 6 - Standardize through visual workplace management

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.
Visual Control Example: Lubrication

Equipment Elements
• "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
Ideas for Visual Control

Step 7 - Implement autonomous equipment management

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
Implementation Audits

1. Proper education and training
 Are the operators certified?
 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
Key Implementation Points of AM

• Active leadership for TPM initiative
• Understanding that AM is owned by Production department and supported by
Maintenance department
• Proper operator training, education and skills certification
• Allocating the time required for cleaning and lubrication & must be included in the daily
schedule
• Supervisors need to ensure that AM activities are performed as per the instruction sheet
How to Sustain AM?

Execute & follow
standards & rules
Examine &
expose problems
Prevent recurrence
through improvement
Counter &
solve problems
Autonomous Maintenance Approach

Recap

In your win, lies our win!
Thank you

Hofincons - TPM Pillar 1 - Autonomous Maintenance (1).pdf

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