th, Autonomous Maintenance - TPM Club SA...AM is the foundation stone of TPM •Activities by...
Transcript of th, Autonomous Maintenance - TPM Club SA...AM is the foundation stone of TPM •Activities by...
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Total productive Maintenance
Autonomous Maintenance
- Step 1
Introduction – Autonomous Maintenance
Autonomous according to the dictionary means ‘independent’, ‘self-sufficient’ or ‘self-governing’
AM is the foundation stone of TPM
• Activities by Operators to create & maintain base
conditions for optimal operation.
• Without operators who can look after their own machines,
losses and break-downs cannot be reduced.
• It is a way to “secure” improvements.
“I am in charge of my machine”
Objective
• Operators become equipment experts
• Problems that stop or slow the machine can be
eliminated by changing the attitude of the people –
Managers, Operators & Technicians In other words
• Zero Defect & Zero Breakdowns can be attained
When:
• equipment works better, people work better
people work better, factory works better
• factory works better, people are happier
7 STEP Implementation
1. Initial Cleaning
2. Counter measures against sources of dirt & difficult
points
3. Develop tentative standards of cleaning,
inspection & lubrication
4. General Inspection
5. Autonomous inspection
6. Standardization
7. Autonomous
Management Stage-3
Standardize maintenance
activities & implement
Autonomous Control
Stage-2
Assessment of the wear on
equipment & Develop activities
to prevent it
Stage-1
Establish Basic Conditions
of the Equipment & Maintain
those conditions
Steps Levels
0. Preparation Get people motivated
Example of Implementation
Issues that Impact OEE
Low operative
efficiency
High # of damages
Deficient
communicacition
High Nº of accidents
Lack of interest of
the operators
Lack of skills
LOSSES DUE TO SETUP
LOSSES DUE TO DEFECT
LOSSES DUE TO RAW MATERIAL
GHEE, THE MARKERS ARE NOT
GETTING BETTER
LACK OF
INTEREST
DIFFICULTY TO MAKE OUT
LACK OF
SKILL
“I OPERATE, YOU REPAIR”
OPERATOR
MAINTENANCE
STAFF
“BE GREATFULL THAT I FIXED YOUR MACHINE”
Selfish attitude
Negative attitude
=
+
NON PRODUCTIVE MAINTENANCE
Issues of Prod & Maint.
TPM View
Operators
Baby Parents Physicians
Machines Maintenance
Operators Should Be Able To
• Understand how the equipment works & identify the causes
of abnormality
• Identify & correct equipment abnormalities
• Understand the relationship between equipment condition &
quality of the product; i.e. foresee quality issues & recognize
the cause.
• Carry our repairs
• Take charge of making improvements; on their own &
through working with other departments
Autonomous Maintenance – Step 1
Step 1 - Initial Cleaning &
Inspection
• Cleaning and Inspection is conducted on the equipment to exposed equipment
abnormalities
• Inspection Means finding problems
• Dust, stains, oils and grease has to be removed
• When cleaning oil leakage, loose wires, unfastened nuts and bolts and worn out
parts must be taken care
• Initial cleaning is not intended to be an overhaul or turn around of the equipment or
process area
• The focus is to increase understanding of the equipment through the cleaning
process
Step 1 – Cleaning & Inspection
A) Meaning of cleaning - Simply stated, removing dust, oil,
stains, cut powder, sludge and other foreign objects from the equipment area.
- Through such activities potential equipment defects are highlighted.
B) Cleaning is inspection
- Confirm safety of cleaning in advance
- Operators should personally engage in cleaning their own work
- Open previously unseen covers or lids
- Disassemble components if necessary with trained maintenance personnel if required.
Step 1 – Initial Cleaning
Step 1 – Hazards of Insufficient Cleaning
Typical hazards that occur from insufficient cleaning include; 1. Causes of failure - Stains and foreign items in revolving units, sliding units, air and oil pressure
systems. Electrical control systems and sensors can also be affected resulting in reduced accuracy, erroneous operation and failures due to resultant wear, clogging, resistance and bad power application.
2. Cause of quality defects 3. Cause of deterioration 4. Cause of speed loss Stains enhance abrasion and sliding resistances, which in turn engender speed losses.
Step 1 – Hard To……. List
Make lists of
Areas/Parts Hard to clean Hard to Lubricate Hard to tighten Hard to adjust Hard to inspect
Record the cleaning time Carry out an audit on step 1 Meeting after daily activities Refer to old history records
Step 1 – Tagging of Hard To…. Areas
Entries in the Hard to list of defects should be tagged on the equipment
• White Tags: Rectified by operator through JH
• Red Tag : Rectified by specialist due to nature of malfunction. White tags would typically include; - Loosening of fitted bolts of limit switches, proximity switched - Replacement of worn screws - Dislocation and twisting of wires - Replacement of damaged V-belts
Step 1 Continued
When exposing defects, it is important to learn how to find these defects and malfunctions. Operators should receive advanced guidance from maintenance on ideal conditions and these should be visualised. Use the five senses to identify abnormal conditions.
Step 1 Continued
Step 1 Continued
Step 1 Continued
Step 1 – Abnormality classification
1. Minor Flaws 2. Unfulfilled basic conditions 3. Inaccessible places 4. Contamination sources 5. Quality defect sources 6. Unnecessary and non urgent items 7. Unsafe places
Refer to JH manual page 72-90
Step 1 – Abnormality classification
Step 1 – Develop Cleaning Maps
Develop drawings or use pre-existing equipment drawings to identify areas to clean that operators can use when doing their daily routine tasks of cleaning is inspecting.
Refer to page 92 and 93 of the JH Manual
Step 1 – Develop Cleaning Maps
Refer to page 92 and 93 of the JH Manual
Summary
Step 1
Autonomous Maintenance
• Operator takes ownership of his/her equipment at all times
• Establish basic conditions of equipment
• Operators become equipment experts