Understanding the Theory of Equipment Operation is the first step in Autonomous Maintenance and Total Productive Maintenance.

1. Theory of Operations

2. Theory of Operation
• Definition: The theory of operation is a description of how a device,
system, or machine is supposed to work
• It will describe the purpose of a machine or system’s various
components and how they interact to deliver quality output
• It is often included in documentation
- Maintenance or service documentation
- User Manual
Description of how a device, system or machine is
supposed to work

3. Theory of Operation
- Aids troubleshooting
- Provides the troubleshooter with a mental model of how the system is
supposed to work
- The troubleshooter can then more easily identify discrepancies, to aid
diagnosis of problem
Ever think a machine’s component can be disabled and not affect
performance?
Aids in diagnosis of the problem

4. Key Components of an
Operations/Maintenance Manual
• Equipment Description
• Description of Components
• Diagram and Parts Listing
• Operating Instructions
• Adjustments
• Troubleshooting Guide
• Cleaning and Inspection Procedures
Theory of Operations

5. Equipment Description Example
The Rayovak model 1234 flashlight is designed to provide economical and
portable light to aid in completing inspection, maintenance and repair activities in
places where ambient lighting is poor. Proper operation and maintenance of your
Rayovak flashlight is essential to ensure long-term reliability.The Rayovak model
1234 flashlight is composed of the three subsystems shown below:
Description of how a device, system or machine is supposed to work

6. Sub System Theory Example
Step 1 – The operator presses the slide switch towards the lamp assembly.
Step 2 – The energizing slide contact connects with the lamp circuit contact.
Step 3 – The shape of the energizing slide contact creates a force fit with the
lamp circuit contact, keeping the slide switch in the ‘on’ position until moved
by the operator.
Step 4 – The de-energizing slide contact remains in contact with the battery
circuit contact through the full range of motion of the switch.
Step 5 – Electrical current at 1.5v (max) and 900mA travels from the battery
circuit contact, through the slide switch and into the lamp circuit contact.
Aids in diagnosis of the problem

7. Example of Theory of Operation – Overall
Bartelt
Description of how a device, system or machine is supposed to work

8. Example of Theory of Operation – Subassembly
Starmatic Labeler
Provides the troubleshooter with a mental model
MACHINE INFEED
•Bottles enter the machine by conveyor in single file.
• Depending on line conditions, bottles will
either be held back by the bottle stop to
accumulate or will pass by the bottle stop
into the feedscrew.
• The feedscrew separates bottles, providing
proper spacing to be accepted by the
infeed star.
• The infeed star then transfers bottles onto the bottle table where they are positioned on bottle
plates and held firmly in place by overhead centering bells.

9. Example of Theory of Operation – Overall
Probat Jupiter Tangential Roaster
Description of how a device, system or machine is supposed to work

10. Functional Mapping / Analysis
If you don’t have a good Theory of Operations, how do you get it?
One way is through Functional Mapping / Analysis
Functional Mapping can be used to clarify the functions of your equipment
It provides a means of formally analyzing the equipment in an FMEA
Functional Mapping can be used to clarify the functions of your equipment

11. Functional Mapping Continued
For each function ask the question:
•Is it necessary?
• Is it Useful?
• Is it Value Added?
Identify all physical objects in the system using your existing knowledge of
the structure
Draw arrows between all objects that represent what action is being done
Identify all physical objects in the system

12. Next Steps
Create a Theory of Operations Manual