Maintenance Autonomous

Titan Industries limited, Watches division, Hosur
Machine Maintenance
Quality Month-2009 Page 1 of 20
Plant Maintenance
Plant Maintenance is the health care of plant. The way preventive medicine
has greatly improved health care for the human body; preventive
maintenance has done the same for manufacturing plants. Failures and
defects are the illness of equipment. To prevent such illness routine
maintenance (cleaning, oiling, tightening, and inspection) must be
implemented. All of us can and must protect the equipment we use
ourselves by regular checkups. This is called Autonomous Maintenance in
TPM terminology.
Total productive maintenance [TPM]
Manufacturing improvement methods, those increase production and
reduce waste through continuous attention to the condition of machines
and processes. TPM's main goal is to maximize equipment usefulness
across its lifespan.
The TPM concept (Total Productive Maintenance) started in the
fabrication and assembly industries in 1971and underwent numerous

Machine Maintenance
subsequent changes. TPM is now rapidly spreading through a wide range
of manufacturing industries, such as the steel making, mass manufacturing,
chemical, food stuffs, and cement industries. TPM, a unique Japanese
system of managerial expertise, was created in 1971, based on the PM
(Preventive maintenance OR Productive maintenance) concept introduced
from the United States in the year 1950.
Many production systems are human-machine systems. Dependence
of production systems on an equipment increases as automation
progresses. And hence the machine efficiency depends on the methods of
manufacturing, usage and maintenance.

Machine Maintenance

Machine Maintenance
The aim of TPM is to maximize the production efficiency by:
1. Preventing the occurrence of stoppage losses due to failures
2. Eliminating the speed losses resulting from minor stoppages
3. Eliminating the defect losses caused by process defects
4. Improving the method of manufacturing
Basic Principles of Quality Maintenance
 Make autonomous Maintenance a habit
 Set standards for normal and abnormal
 Strictly follow all standards and rules
 Discover any equipment abnormalities that could cause defects
 Immediately begin proper treatment for any abnormalities
 Improve equipment conditions and train operators
5S
Problems cannot be clearly seen when the work place is unorganized.
Cleaning and organizing the workplace helps the team to uncover
problems. Making problems visible is the first step of improvement.
Japanese Term English Translation Equivalent 'S' term
Seiri Organisation Sort
Seiton Tidiness Systematise
Seiso Cleaning Sweep
Seiketsu Standardisation Standardise
Shitsuke Discipline Self - Discipline

Machine Maintenance
Maintenance Terms and Terminology
Availability
The percentage of time a machine is actually able to produce parts out
of the total time that it should be able to produce. This number includes
breakdowns, setups, and adjustments.
Basic condition
The expected good state of repair that equipment should possess in
order to produce quality parts in a timely manner. Under TPM, operators
are expected to maintain their machine's basic condition.
Breakdown maintenance
Maintenance performed on broken machines to restore them to working
order.
Continuous improvement
Replacing ineffective practices, machines or manufacturing processes
with effective ones; To achieve ongoing measurable gain. Organizations
must constantly measure the effectiveness of processes and strive to
meet more difficult objectives to satisfy customers.
Downtime
Downtime is the period of time when a machine or a factory is not
operating and is not producing.
Overall equipment effectiveness
OEE; The percentage of equipment's availability, quality, and
performance multiplied together.
Performance rate
The rate parts are produced divided by the machine capacity. This
number includes the number of parts produced in a given time, reduced
speeds, idling, and short-term stoppage for jams and other problems.

Machine Maintenance
Periodic maintenance
Maintenance performed on a calendar basis.
Planned maintenance
Maintenance that is performed purposely and regularly in order to
prevent a machine from deteriorating or breaking down.
Predictive maintenance
Maintenance performed based on the known and expected behavior,
condition, and history of the machine.
Preventive maintenance
Maintenance performed while a machine is still in working order to keep
it from breaking down. Preventive maintenance includes lubricating,
tightening, and replacing worn parts.
Mean Time Between Failures (MTBF)
MTBF is a basic measure of reliability for repairable items. It can be
described as the number of hours that pass before a component,
assembly, or system fails. It is a commonly-used variable in reliability
and maintainability analyses.
Mean Time To Failure (MTTF)
MTTF is a basic measure of reliability for non-repairable systems. It is
the mean time expected until the first failure of a piece of equipment.
MTTF is a statistical value and is meant to be the mean over a long
period of time and large number of units. For constant failure rate
systems, MTTF is the inverse of the failure rate.

Machine Maintenance
Autonomous Maintenance
Maintenance that is performed by the person who runs the machine
rather than the maintenance staff is Autonomous Maintenance.
Autonomous maintenance includes tasks such as lubricating and
tightening machine parts. As most of the Lean Manufacturing techniques
and tools, autonomous maintenance is based on education and training.
It is about raising awareness of the person on the knowledge and
understanding the operation principles of their machines. We can
perform following activities to maintain the equipment in productive
condition.
 Daily checks
 Lubrication
 Replacement of parts
 Repairs
 Precision checks
 Early detection of abnormal conditions

Machine Maintenance
Three Skills
To practice autonomous maintenance, we must learn three skills. These
skills enable us to predict and take necessary action to prevent failure
and improve efficiency of machine.
1. Ability to determine and judge if operating conditions become
abnormal
Ability to determine abnormality is one of the key skill we should
posses. Without understanding the operation condition and
abnormality, we cannot anticipate the behavior of machine and
hence will fail to foresee the future failures.
2. Ability to preserve normal conditions
The next step, after identifying the abnormality, is to choose the
correct action to prevent it. Every problem has many root causes and
can be corrected in different ways. The person who runs the
machine knows different aspects of machine (tangible and intangible)
and therefore is the best man to know the influential parameters.
3. Respond quickly to abnormalities
After analyzing the abnormal condition and preparation of action plan,
Execution must be done as soon as possible. Without this final step
the first two steps doesn’t produce any result and the failure will be
unavoidable. To prevent anticipated failure, action should be
performed to correct abnormality and bring the machine back in
normal condition.

Machine Maintenance
7 steps of Autonomous Maintenance
1. Clean the machine.
2. Take measures to tackle the causes and the results of dust, oil and
dirt.
3. Develop standards and procedures for cleaning and oiling.
4. Adequate training to be effective inspectors.
5. Set-up inspection lists that will enable production employees to
keep the machines in optimum condition.
6. Develop standards and procedures to organize the workfloor
(including safety, health, order and cleanness).
7. Implement a totally autonomous maintenance system.
Steps involved in each activity
1. Initial cleaning
Major Activities
 Thoroughly clean equipment and its surroundings
 Remove all unnecessary materials
 Write upcoming issues onto four lists
Equipment perspective
 Expose hidden defects by removing contaminants
 Restore defective areas in equipment
 Identify sources of contamination
Human Perspective
 Become familiar with group activity by way of easy tasks
such as cleaning
 Group leaders learn leadership

Machine Maintenance
 Look at and touch every corner of equipment to enhance its
care and to promote curiosity and questions
 Learn "Cleaning is inspection"
Manager Support
 Lead by staying one step ahead, comprehending TPM
through practice, and demonstrating with examples of mana-
gers' models
 Teach defects of equipment
 Teach importance of cleaning, lubrication and tightening
 Teach "Cleaning is inspection"
2. Countermeasures to sources of contamination
Major Activities
 Remedy sources of contamination
 Prevent contaminants from irregular and undesirable
dispersion
 Improve difficult cleaning areas to reduce cleaning times
 Equipment perspective
 Prevent contaminants from generating and adhering to equip-
ment in order to enhance reliability
 Definitely maintain equipment cleanliness so as to improve
maintainability
Human Perspective
 Learn motion and working mechanism of machinery
 Learn methods to improve equipment focused on sources of
contamination
 Encourage interest and desire to improve equipment

Machine Maintenance
 Feel pleasure and satisfaction with successful achievement
of improvement
Manager Support
 Teach motion and working mechanism of machinery
 Teach where-where and why-why analyses to examine pro-
blem
 Assist in implementing ideas for improvement
 Promptly respond to work orders

Machine Maintenance
3. Cleaning and lubrication standards
Major Activities
 Conduct education for lubricating
 Develop overall lubrication inspection
 Establish lubrication control system
 Set cleaning and lubrication standards
 Equipment perspective
 Correct difficult lubricating areas
 Apply visual controls
 Definitely maintain basic equipment conditions (cleaning, lu-
bricating, tightening) to establish deterioration prevention
system
Human perspective
 Set rules by oneself and follow them
 Know importance of following rules and autonomous supervi-
sion
 Encourage awareness of one's own roles and teamwork
Manager Support
 Prepare lubrication control rules
 Provide education and practice in terms of lubrication
 Teach how to prepare cleaning and lubricating standards
 Assist actual preparation of standards

Machine Maintenance
4. Overall inspection
Major Activities
 By each inspection category:
 Conduct education and practice
 Develop overall inspection
 Remedy difficult inspection areas in equipment to reduce
required time
 Set tentative inspecting standards
 Detect and remedy minute defects
 Thoroughly apply visual controls
 Improve difficult inspection areas
 Maintain established equipment conditions by means of rou-
tine inspection to improve reliability further
Human perspective
 Learn structure, function and inspection methods of equ-
ipment to master inspection skill
 Master easy servicing procedures
 Group leaders learn leadership through conducting roll-out
education
 Learn recording, summarization and analysis of inspection
data
Manager Support
 Prepare overall inspection schedule, check sheets, manuals,
and other teaching materials
 Promptly respond to work orders
 Provide training for easy servicing
 Teach how to improve difficult inspection areas by applying
visual controls thoroughly
 Teach inspection data handling

Machine Maintenance
5. Autonomous Maintenance standards
Major Activities
 Set autonomous maintenance standards and schedule to
finalize activities focused on equipment
 Faithfully conduct routine maintenance in accordance with
standards
 Move forward aiming at Zero Breakdowns
Equipment Perspective
 Assess successful remedies achieved in other processes,
and apply them to similar equipment
 Totally review visual controls
 Preserve equipment in highly reliable condition along with
operability and maintainability
 Realize an orderly shop floor
Human perspective
 Understand equipment as a total system
 Develop ability to detect signs of abnormalities to prevent
breakdowns
 Train knowledgeable operators
 Establish autonomous supervision system conducted by PM
group
Manager Support
 Allocate inspection work
 between autonomous and full-time maintenance
 Teach basic maintenance skill and easy machine diagnosis
 Teach examples of breakdown prevention
 Teach particular function of each piece of equipment to
understand equipment as a system

Machine Maintenance
6. Organisation
Major activities
 Prevent outflow of defective products to downstream proces-
ses
 Prevent manufacturing of defective products
 Attain process quality assurance and move forward aiming at
Zero Defects
Equipment Perspective
 Assess process quality
 Attain a reliable process to prevent outflow of quality defects
 Assess quality conditions
 Attain a highly reliable process to prevent manufacturing of
quality defects.
Human perspective
 Train knowledgeable operators on equipment and quality
aiming at new type of engineering status
 Attain autonomous supervision within each operator
Manager Support
 Teach quality specifications, quality causes and quality re-
sults along with their relationship
 Teach the five criteria for ease of observation
 Teach the five criteria for quality assurance
 Address matters of quality with cooperation by all related
departments

Machine Maintenance
7. Autonomous maintenance
Major Activities
 Maintain, improve and pass on current TPM levels
 Calculate the Overall Equipment Effectiveness (O.E.E.)
 Analysis of the failure of the equipment
 Predict abnormalities to prevent breakdowns and quality de-
fects prior to occurrence
 Attain Zero Accidents, Zero Breakdowns
 Move forward aiming at higher level of production technology
Human Perspective
 The O.E.E. shows the week spots of the equipment
 Firmly establish self-supervision to be able to develop
factory's strategy by SGA groups themselves without mana-
gers' detailed instruction
 Detect and resolve arising problems by SGA groups
themselves by way of short remedial program
Manager Support
 Assisting with the calculation of the O.E.E.
 Assist activities to maintain, improve and hand down current
TPM status
 Encourage further improvement of technical knowledge and
skills
 Move forward toward the second generation of TPM

Machine Maintenance
KAIZEN
"Kai" means change, and "Zen" means good (for the better). Basically
kaizen is for small improvements, but carried out on a continual basis
and involve all people in the organization. Kaizen is opposite to big
spectacular innovations. Kaizen requires no or little investment. The
principle behind is that "a very large number of small improvements are
more effective in an organizational environment than a few
improvements of large value. This pillar is aimed at reducing losses in
the workplace that affect our efficiencies. By using a detailed and
thorough procedure we eliminate losses in a systematic method using
various Kaizen tools. These activities are not limited to production
areas and can be implemented in administrative areas as well.
Kaizen Policy
1. Practice concepts of zero losses in every sphere of activity.
2. relentless pursuit to achieve cost reduction targets in all resources
3. Relentless pursuit to improve over all plant equipment
effectiveness.
4. Extensive use of PM analysis as a tool for eliminating losses.
5. Focus of easy handling of operators.
Kaizen Target
Achieve and sustain zero loses with respect to minor stops,
measurement and adjustments, defects and unavoidable downtimes. It
also aims to achieve 30% manufacturing cost reduction.

Machine Maintenance
Tools used in Kaizen
1. PM analysis
2. Why - Why analysis
3. Summary of losses
4. Kaizen register
5. Kaizen summary sheet.
The objective of TPM is maximization of equipment effectiveness. TPM
aims at maximization of machine utilization and not merely machine
availability maximization. As one of the pillars of TPM activities, Kaizen
pursues efficient equipment, operator and material and energy utilization
that is extremes of productivity and aims at achieving substantial effects.
Kaizen activities try to thoroughly eliminate 16 major losses.

Machine Maintenance
16 Major losses in an organisation
Loss Category
1. Failure losses - Breakdown loss
2. Setup / adjustment losses
3. Cutting blade loss
4. Start up loss
5. Minor stoppage / Idling loss.
6. Speed loss - operating at low speeds.
7. Defect / rework loss
8. Scheduled downtime loss
Losses that impede
equipment efficiency
9. Management loss
10. Operating motion loss
11. Line organization loss
12. Logistic loss
Loses that impede
human work efficiency

Machine Maintenance
13. Measurement and adjustment loss
14. Energy loss
15. Die, jig and tool breakage loss
16. Yield loss.
Loses that impede
effective use of
production resources
Classification of losses
Aspect Sporadic Loss Chronic Loss
Causation Causes for this failure can
be easily traced. Cause-
effect relationship is simple
to trace.
This loss cannot be easily
identified and solved. Even
if various counter measures
are applied
Remedy Easy to establish a
remedial measure
This type of losses are
caused because of hidden
defects in machine,
equipment and methods.
Impact / Loss A single loss can be costly A single cause is rare - a
combination of causes
trends to be a rule
Frequency of
occurrence
The frequency of
occurrence is low and
occasional.
The frequency of loss is
more.
Corrective
action
Usually the line personnel
in the production can
attend to this problem.
Specialists in process
engineering, quality
assurance and
maintenance people are
required.

Maintenance Autonomous

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