1. Autonomous Maintenance
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2. Aims & Objectives Target Audience : Purpose of Module :
Autonomous Maintenance Champions, Production Teams.
Purpose of Module :
To equip attendees with the knowledge & understanding to participate in Autonomous Maintenance Activities, in order to deliver tangible and sustainable improvements in equipment reliability
Aims & Objectives :
Outline the Steps of AM
Give Practical Guidance on AM roll out
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3. What is Autonomous Maintenance?
An operator Skill development Programme
An approach to allow problems to be identified and solved quickly
An approach to stop accelerated deterioration of plant and equipment
An approach to stop deterioration related failures
An approach to stabilise equipment conditions (standards)
An approach to develop training materials on how to run, operate & maintain equipment
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4. What is Effective Maintenance?
An Effective Maintenance system will support Autonomous Maintenance.
Effective Maintenance should also involve all areas of the organisation.
Information is key.
Operator and Maintainer training
Up-skill Maintenance to be trainers and equipment improvers
Up-skill Operators to be equipment maintainers (Autonomous Maintenance)
Act
Plan A P D
Check C Do
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5. How do we Implement Autonomous Maintenance?
IMPROVE HUMAN RESOURCES
IMPROVE PLANT AND EQUIPMENT
IMPROVE CORPORATE CULTURE
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6. How do we Implement Autonomous Maintenance?
Step 4 - Finalise Standards & Train
Step 3 - Develop ‘Provisional’ Standards
Outline each of the steps of Autonomous Maintenance that the presentation will cover.
Step 2 - Eliminate Contamination & Inaccessible areas
Step 1 - Initial Clean & Inspect
Step 0 - Education - Machine Function

7. How does Autonomous Maintenance Work?
Change in culture
Move from
reactive to
proactive
Evidence of success
Change
equipment
condition
Effect
working
environment
changes
Effect
Reduced
defects &
failures
Team members
change
Zero defects &
failures are
realised
Change in activities
Positive participation
Kaizen thoroughness
of maintenance
& control
* Understanding the machine functions
Cleaning is inspection
* Inspection can detect abnormalities
* Abnormalities can be rectified
Improve skills
Develop confidence
in their abilities
Teams practice
autonomous kaizen
Very briefly run through the boxes on the slide (From left to right) to outline the changes that will occur through AM over time.
TIME

8. How does Autonomous Maintenance Work?
The way that the stages of autonomous maintenance are described as steps, promotes how autonomous maintenance works.
To get from the bottom to the top it is easier to use evenly spaced comfortably sized steps.
You must maintain each step as you progress, or the whole thing will crumble
Step 4
Step 4
Step 3
Step 2
Step 1
Step 0
Run through the slide

9. The 5 Steps of Autonomous Maintenance
Introduce new step
Step 0 - Education - Machine Function

10. Step 0 - Education - Machine Function
Step 0 is about increasing our basic understanding of machine components and function.
To help us with this we utilise the knowledge of engineers, and use machine components sheets to store this information.
Run through the slide

11. Eg. Machine Components Sheet
Step 0 - Education - Machine Function
Machine Component Sheets help us to understand how equipment works, and what can cause it to fail
They also make a very effective training aid
Eg. Machine Components Sheet
Run through the slide

12. Step 0 - Education - Machine Components Sheets
How Does It Work?
Run through a pre prepared Blank Component sheet
Explain that skilled engineers must facilitate the completion of a sheet with the team.
How Can it Fail?

13. Step 0 - Education - Machine Components Sheets
TIPS
Should Initially be Hand drawn
Should be completed at the machine in question
Should be led by an experienced engineer
Explain each of the tips to ensure that the session runs effectively.
Go onto the shop floor and complete a component sheet on a ‘pilot’ piece of equipment or machinery. (45 minutes)
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14. Step 0 - Education - One Point Lessons (OPL’s)
Tool to Communicate Improvements
Tool to capture ideas
Tool to share knowledge
Tool for effective training
Three types of OPL
Basic Knowledge
Improvement Idea
Downtime Problem
Gauge needs to read between red markers within green zone.
Run through a prepared One Point Lesson.
Run through each of the points to explain the value of OPL’s
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15. Step 0 - Education - One Point Lessons (OPL’s)
TIPS
Should Initially be Hand drawn
Should be 80% Drawing 10% Words
Should only take 5 mins to teach
Adopt a company numbering system
Should be verified by an engineer
Use the bottom of the sheet as a training record
Gauge needs to read between red markers within green zone.
Explain each of the tips to ensure that the session runs effectively.
Go onto the shop floor and complete a one point lesson on a ‘pilot’ piece of equipment or machinery. (45 Minutes)
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16. Step 0 - Education - Instructional Videos
Guidelines
Keep it Simple
Use Own Staff
Humour
Maximum 20 mins
Plan the video
Communicate intention to all staff
Run through the slide
Sell the benefits of video :-
Training Aid
Consistent Communication
Fun to do
Can get a lot of info over quickly
Go onto the shop floor and produce and instructional video for a specific operation relating to your pilot area. (Obtain permission first) (90 Minutes)
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17. Under Pinning Knowledge
Step 0 - Education - Skills Audit
Guidelines
Based on detailed checklists that include
Skills and Knowledge Required to complete Tasks
Notes on how to carry out assessments
Based on standard work instructions
Under Pinning Knowledge
Process AM Skills
Explain each of the tips to ensure that the session runs effectively.
(NB:-Skills may be taken from departmental Work Instruction Sheets.)
Explain that each area will have key skills and knowledge that operators require in order to ensure the smooth running of plant and equipment - Operators will therefore need to be trained in these skills
Training Matrix
Trained
A N Other
Team 1
J Bloggs
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18. The 5 Steps of Autonomous Maintenance
Introduce the next step
Step 1 - Initial Clean & Inspect
Step 0 - Education - Machine Function
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19. Step 1 - Initial Clean and Inspect
Problem Detection
Restoration
Set Standards
Machine Awareness
Outline each of the key points.
Cleaning IS Inspection!
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20. Step 1 - Initial Clean and Inspect
Machine concern / fault analysis
Example of how cleaning is the first stage to Total Productive Maintenance.
In a Autonomous Maintenance programme, this step introduces the concept of solving problems in the area,particularly machine or equipment related problems.The saying is that ’through cleaning you touch ,through touching you find when you find you fix’.Use cleaning to inspect equipment and find abnormalities early.
The photo is a machine were a concern/fault analysis activity was conducted.
…..through cleaning you touch, through touching you find
when you find, you fix !!
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21. Clean & Inspection Fault Finding Sheet
Machine:
M/c 1265
Date: 15/08
Completed by: J Brown No
Location / Fault
Code
class
Cause
Temp
Perm
Countermeasure
Who
When 1
Pressure Gauge not
within limit H3
Poor labelling T P
Ensure manual setting on
label
Write Setting on Setting
sheet
Team
1/11 2
Measuring probe
unprotected next to
pallet E9
Poor design
Cover to be made
Review machine
specification
NCMT MR
Wk 26 3
Oil Leak next to
twin pallet L4
Poorly installed
Fix leak
Review installation
procedure
Maint
Wk 25
Wk 27 E
Electrical M
Mechanical L
Lubrication H
Hydraulic
Pneumatic W
Water
Class
Loose
Worn
Broken 4
Leaking 5
Missing 6
Dirty 7
Difficult to clean 8
Location / Routing 9
Take the delegates through how the sheet is used.
Relate the included text example back the the machine on the previous slide.
Explain the coding system and give the following example :-
Example No Code Class - H3
H - Hydraulic
3 - Broken
(Give further examples of the codes if necessary)
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22. Clean & Inspection Fault Finding Sheet
Machine:
Completed by: No
Location / Fault
Code
class
Cause
Temp
Perm
Countermeasure
Who
When E
Electrical M
Mechanical L
Lubrication H
Hydraulic P
Pneumatic W
Water
Class 1
Loose 2
Worn 3
Broken 4
Leaking 5
Missing 6
Dirty 7
Difficult to clean 8
Location / Routing 9
Poor design
Date
Blank sheet of the Clean and Check Fault Finding Sheet.
Go onto the shop floor and complete a clean and check fault finding sheet sheet on a ‘pilot’ piece of equipment or machinery. (45 minutes)
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23. Clean & Inspection Concern/Fault Analysis Sheet
CODE CLASS
E = ELECTRICAL
M = MECHANICAL
L = LUBRICATION
H = HYDRAULIC
W = WATER
P = PNEUMATIC
1 = LOOSE
2 = WORN
3 = BROKEN
4 = LEAKING
5 = MISSING
6 = DIRTY
7 = DIFFICULT TO CLEAN
8 = LOCATION & / OR ROUTING
9 = POOR DESIGN
Concern / Fault Analysis sheet is used after machine Clean and Check stage to analyse faults and concerns that need to be fixed
Complete a concern/fault analysis sheet on a ‘pilot’ piece of equipment or machinery.
(30 minutes)
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24. Makes defects easier to detect. Better customer perception.
Creates a better working environment.
Aids efficiency and reduces accidents.
Helps standardisation.
Explain the key learning points from each stage.
Give examples for each of the bullet points.
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25. The 5 Steps to Autonomous Maintenance
Introduce the next step
Step 2 - Eliminate Contamination & Inaccessible areas
Step 1 - Initial Clean & Inspect
Step 0 - Education - Machine Function
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26. Step 2 - Eliminate Contamination and Inaccessible Areas
Quick Correction
Maintain Cleaning Standards
Reduces Inspection Time
Explain each of the tips to ensure that the session runs effectively.
Makes Maintenance Easier
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27. Planned Maintenance - Initial Equipment Survey
Tag 1
Tag 2
Tag 3
Tag 4
Tag 5
Tag 6
Tag 7
Tag 8
Tag 9
MACHINE MAPPING
Group exercise.
Lead by an experienced
engineer/maintainer.
Use in conjunction with “Tags”.
Explain each of the tips to ensure that the session runs effectively.
Outline the benefit of capturing the problems so that tags are not removed until the problem is solved. Tags Lead to Action.
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28. Step 2 - Eliminate Contamination - Machine Mapping
Tag 1
Tag 2
Tag 3
Tag 4
Tag 5
Tag 6
Tag 7
Tag 8
Tag 9
TIPS
Group Exercise
Identify Sources of contamination
Identify inaccessible areas
Should be led by an experienced engineer
Can be used in conjunction with a red tag exercise
Explain each of the tips to ensure that the session runs effectively.
Complete a Machine Map on a ‘Pilot’ piece of equipment or machinery. (45 minutes)
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29. Step 2 - Eliminate Inaccessible Areas - Machine Mapping
TIPS
Aim to reduce cleaning time
Aim to reduce inspection time
Make essential equipment access easier
Simplify equipment operations
The slide shows how Perspex guarding has been used in place of ‘solid’ guarding.
This is to aid essential visual inspections by reducing time taken (through not having to remove guards), and also increasing the frequency of inspection (through checks being carried out naturally during the course of work)
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30. The 5 Steps to Autonomous Maintenance
Step 3 - Develop ‘Provisional’ Standards
Explain each of the steps to ensure that the session runs effectively.
Step 2 - Eliminate Contamination & Inaccessible areas
Step 1 - Initial Clean & Inspect
Step 0 - Education - Machine Function
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31. Step 3 - Develop Provisional Standards
Schedules
Cleaning Standards
Lubrication Standards
Inspection Standards
Outline each of the components.
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32. Step 3 - Develop Provisional Standards - Cleaning, Lubrication and Inspection
Date:
Machine:
Cleaning Items
Lathe
Process:
JIG REMOVAL C
Item to Clean 1
LOCATING PINTLE 2
AREA AROUND SHAFT 3
SUPPORTING ACTUATOR SHAFT 4
GENERAL AREA
C1 + D1
Lubrication & Inspection Items D
Item 1
LOCATING PINTLE - INSPECT FOR
Run through each stage of the cleaning lubrication and inspection sheet.
Explain its value as a training aid.
Explain the value of inspection and lubrication schedules. If available show some current department schedules.
AM inspection and lubrication schedules will be developed with engineers after AM training has been undertaken.
Complete a Cleaning Lubrication & Inspection Sheet on a ‘Pilot’ piece of equipment or machinery. (Optional)
WEAR, LUBE WHERE NECESSARY 2
SUPPORTING ACTUATOR SHAFT -
C3 + D2
AS ABOVE 3
REPORT ANY DAMAGE TO TEAM
LEADER
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33. The TPM Board Policy Goals Targets Before / After Photos Before /
Hard To Access Areas
Countermeasures
OPL’s
Machine Component Sheets
Improvement OPL’s
Audit
Checklist
30 Problem
List
An example of the content of an AM Storyboard. A storyboard is an essential tool to communicate the activities and successes of a team, that’s progressing through AM implementation. The content for the board needs to be chosen by the team, and may change from department to department.
The boards needs to updated on a regular basis and reflect the AM activities that are taking place.
The board should also be located in a position where the whole team can view the information. (eg near an amenity area etc)Produce an AM Board based on the above template, using all the info that has been produced during the course. This should then be presented by the team to management. (1 Hour)
Radar
Chart
Red Tag
Record
Sheet
Efficiency Chart
Box of
Red Tags
Graph Of Problem Areas
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34. The TPM Board TIPS Display all work from steps 1 - 3
Locate the board in the work area
Present the board & improvements to senior mangers
Ensure that the board is up to date and owned
Establish a standard that other boards can adopt
Explain each of the tips to ensure that the session runs effectively.
(The board is an example from a Unilever Factory)
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35. The 5 Steps to Autonomous Maintenance
Step 4 - Finalise Standards & Train
Step 3 - Develop ‘Provisional’ Standards
Explain each of the tips to ensure that the session runs effectively.
Step 2 - Eliminate Contamination & Inaccessible areas
Step 1 - Initial Clean & Inspect
Step 0 - Education - Machine Function
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36. Step 4 - Finalise Standards and Train
Standard Practice
Management Buy Off
Structured Training
Effective Knowledge Management
Outline each of the key Points.
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37. Step 4 - Finalise Standards and Train - Deployment
Trainers
Group
leaders AM
All the operators
Outline your own departments roll out plan.
Underline the fact that this can only work with everyone’s involvement.
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38. Step 4 - Finalise Standards and Train - Training Contents
Training Should Include:-
Parts names, structure and function of equipment
Problems and their corrective actions
Keypoints, methods, and criteria for inspection
Inspection practice
Explain each of the tips to ensure that the session runs effectively.
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39. Step 4 - Finalise Standards and Train - Training Contents
Training Should Include:-
Component Sheets
One Point Lessons
Standards
Work Instruction Sheets
Gauge needs to read between red markers within green zone.
Explain each of the tips to ensure that the session runs effectively.
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