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5. AUTONOMOUS MAINTENANCE AND SMALL GROUP ACTIVITIES


Autonomous Maintenance


The principal way in which the production department participates in TPM is through
autonomous maintenance- cleaning, inspection, and simple adjustments performed by operators
systematically trained through a step-by-step programme.
The purpose of an autonomous maintenance program is threefold. First, it brings production and
maintenance people together to accomplish a common goal – to stabilize equipment conditions
and halt accelerated deterioration. Operators learn to carry out important daily tasks that
maintenance personnel rarely have time for. These tasks include cleaning and inspection,
lubrication, precision checks, and other light maintenance tasks, including simple replacements
and repairs in some environments.
Second, an autonomous maintenance program is designed to help operators learn more about how
their equipment functions, what common problems can occur and why, and how those problems
can be prevented by the early detection and treatment of abnormal conditions. Third, the program
prepares operators to be active partners with maintenance and engineering personnel in
improving the overall performance and reliability of equipment.
Traditionally, the general attitude on the shop floor has been “I run it, you fix it”. Operators were
responsible only for setting up workplaces, operating the equipment, and checking the quality of
processed work. All management of the equipment’s condition was the responsibility of
maintenance staff. By now it should be clear that this way of thinking does not promote optimal
equipment performance.
The alternatives are sad indeed, because as operators you can easily prevent many breakdowns
and quality problems by learning how to recognize abnormal conditions. A great deal of this
learning can come about simply through your physical contact with the equipment – by taking a
little time to tighten loose bolts, lubricating dry parts and cleaning away dirt, and by noticing dirt
or grime on friction surfaces and switches – conditions that can shorten equipment life.
While these tasks are easy enough to do, in very few factories are they done well. Often you can
find clogged drains, empty oil supply equipment, and other results of neglect.
Autonomous maintenance teaches you, the equipment operator, to understand your equipment.
Equipment knowledge is no longer limited to operation; now it also includes a lot of things
traditionally regarded as maintenance work. This approach is becoming increasingly important as
factories introduce more robots and automated systems. Most important, you need the ability to
look at the quality of the products and the performance of the equipment and notice when
something is not right.
This depends on the following three skills:
   1.   Knowing how to distinguish between normal and abnormal conditions (the ability to establish
        equipment conditions).
2.   Knowing how to ensure that normal equipment conditions are met (the ability to maintain
        equipment conditions).
   3.   Knowing how to respond quickly to abnormalities (the ability to restore equipment conditions).
When you have mastered all three skills, you will understand the equipment well enough to
recognize the causes of future problems. You will realise when the machine is about to produce
defects or break down. You will also be able to respond quickly. The following list describes
some of the skills operators' need.
The ability to detect, correct, and prevent equipment abnormalities and make improvements.
This includes understanding the important of
   1.   Proper lubrication, including correct lubrication methods and methods for checking lubrication.
   2.   Cleaning (inspection) and proper cleaning methods.
   3.   Improving equipment to reduce the amount of debris and prevent its accumulation and spread.
   4.   Improving operation and maintenance procedures to prevent abnormalities and facilitate their
        prompt detection.
The ability to understand equipment functions and mechanisms, and the ability to detect
causes of abnormalities.
   1.   Knowing what to look for when checking mechanisms.
   2.   Applying the proper criteria for judging abnormalities
   3.   Understanding the relations between specific causes and abnormalities.
   4.   Knowing with confidence when the equipment needs to be shut off.
   5.   Being able to diagnose the causes of some types of failures.
The ability to understand the relationship between equipment and quality, and the ability to
predict problems in quality and detect their causes
   1.   Knowing how to conduct a physical analysis of the problem.
   2.   Understanding the relationship between product quality characteristics and equipment
        mechanisms and functions.
   3.   Understanding tolerance ranges for static and dynamic precision, and how to measure such
        precision.
   4.   Understanding the causes of quality defects.


The ability to make repairs.
   1.   Ability to replace parts.
   2.   Understanding of life expectancy of parts.
   3.   Ability to deduce causes of breakdowns.
   4.   Ability to take emergency measures.
   5.   Ability to assist in overhaul repairs.
Obviously, anyone who masters all these skills has achieved a very high level indeed, and no one
is expected to do hat quickly. Instead, each skill should be studied and practiced for whatever
time it takes to acquire proficiency.
Implementing Autonomous Maintenance in Seven Steps
Table below outlines the seven developmental stages of an autonomous maintenance program.
These stages or steps are based on the experiences of many companies that have successfully
implemented TPM They represent an optimal division of responsibilities between production and
maintenance departments in carrying out maintenance and improvement activities.
A Step -by -Step Approach
It is very difficult to do several things at the same time. That’s why autonomous maintenance
training takes a step-by-step approach, making sure each key skill is thoroughly learned before
going on to the next. Autonomous maintenance is implemented in seven steps:
       Step 1 : Conduct initial cleaning and inspection
       Step 2 : Eliminate sources of contamination and inaccessible areas.
       Step 3:Develop and test provisional cleaning, inspection and lubrication standards.
       Step 4: Conduct general inspection training and develop inspection procedures.
       Step 5 : Conduct general inspections autonomously.
       Step 6 : Organise and manage the workplace.
       Step 7:Ongoing autonomous maintenance and advanced improvement activities.
Seven Steps for Developing Autonomous Maintenance

Step              Activity                               Goals for Equipment                  Goals for Group Members
                                                         (workplace diagnosis)                (TPM group diagnosis

1.Conduct         Thoroughly remove debris and           Eliminate environmental causes       Develop curiosity, interest, pride
initial           contaminants from equipment            of deterioration such as dust and    and care for equipment through
cleaning          (remove unused equipment parts)        dirt;     prevent     accelerated    frequent contact
                                                         deterioration
                                                                                              Develop     leadership      skills
                                                         Eliminate dust and dirt; improve     through small group activities
                                                         quality of inspection and repairs
                                                         and reduce time required
                                                         Discover    and    treat   hidden
                                                         defects



2.Eliminate       Eliminate the sources of dirt and      Increase inherent reliability of     learn equipment improvement
sources      of   debris; improve accessibility of       equipment by preventing dust         concepts and techniques, while
contamination     areas that are hard to clean and       and other contaminants from          implementing        small-scale
and               lubricate; reduce time required for    adhering and accumulating            improvements
inaccessible      lubrication and cleaning
                                                         Enhance maintainability by           Learn     to     participate in
areas
                                                         improving   cleaning    and          improvement      through small
                                                         lubricating                          group activity
                                                                                              Experience the satisfaction of
                                                                                              successful improvements

3.Develop         Set clear cleaning, lubrication and    Maintain      basic    equipment     Understand the meaning and
cleaning and      inspection standards that can be       conditions(deterioration-            importance of maintenance by
lubrication       easily maintained over short           preventing activities) cleaning,     setting maintaining our own
                  intervals; the time allowed for        lubrication, and inspection          standards (What is equipment
                  daily/periodic work must be clearly                                         control?)
                  specified
                                                                                              Become better team members by
                                                                                              taking on more responsibility
                                                                                              individually.

4.Conduct         Conduct training on inspection         Visually inspect major parts of      Learn equipment mechanisms,
general           skills   in    accordance       with   the      equipment;        restore   functions, and inspection criteria
inspection        inspection manuals; find and           deterioration;enhance reliability    through inspection training,
skills training   correct minor defects through                                               master inspection skills
                                                         Facilitate inspection through
                  general         inspections;modify
                                                         innovative methods, such as          Learn to perform simple repairs
                  equipment to facilitate inspection
                                                         serial number plates, colored
                                                                                              Leaders enhance leadership skill
                                                         instruction labels, thermotape
                                                                                              through teaching group members
                                                         gauges and indicators see
                                                                                              learn through participation
                                                         through covers etc.
                                                                                              Sort out and study general
                                                                                              inspection data;
                                                                                              Understand the importance of
                                                                                              analyzed data.
5.Conduct       Develop and use autonomous            Maintain optimal equipment           Draw up individual daily and
inspection      maintenance       check      sheet    conditions once deterioration is     periodic check sheets based on
autonomously    (standardize cleaning, lubrication,   restored through        general      general inspection manual and
                and inspection standards for ease     inspection                           equipment data and develop
                of application)                                                            autonomous management skills
                                                      Use innovative visual control
                                                      systems to make cleaning             Learn importance of basic data-
                                                      lubrication/inspection  more         recording
                                                      effective
                                                                                           Learn proper operating methods,
                                                      Review equipment and human           signs of abnormality, and
                                                      factors;   clarify abnormal          appropriate corrective actions.
                                                      conditions
                                                      Implement improvement           to
                                                      make operation easier.

6.Organize      Standardize various workplace         Review and       improve    plant    Broaden      the  scope      of
and manage      regulations;improve           work    layout etc.                          autonomous maintenance by
the workplace   effectiveness,product quality, and                                         standardizing           various
                                                      Standardize control of work-in-
                the safety of the environment                                              management and control items
                                                      process defective products, dies,
                Reduce setup and adjustment time;     jigs,     tools         measuring    Be conscious of the need to
                eliminate work-in-prices              instruments, material handling       improve       standards       and
                                                      equipment, aisles, etc.              procedures continuously, based
                Material handling standards on the
                                                                                           on a standardization practice and
                shop floor                            Implement      visual   control
                                                                                           actual data analysis
                                                      systems      throughout     the
                Collecting and recording data:
                                                      workplace                            Managers and supervisors are
                standardization
                                                                                           primarily    responsible   for
                Control standards and procedures                                           continuously         improving
                for raw materials, work-in-process,                                        standards and procedures and
                products, spare parts, dies, jigs,                                         promoting them on the shop
                and tools                                                                  floor

7.Carry out     Develop company goals; engage in      Collect and analyze various          Gain heightened awareness of
ongoing         continuous            improvement     types     of   data;    improve      company goals and costs
autonomous      activities;improve equipment based    equipment to increase reliability,   (especially maintenance costs)
maintenance     on careful recording and regular      maintainability and ease of
                                                                                           Learn to perform simple repairs
and advanced    analysis of MTBF                      operation
                                                                                           through training on repair
improvement
                                                      Pinpoint      weaknesses      in     techniques
activities
                                                      equipment based on analysis of
                                                                                           Learn data collection and
                                                      data, implement improvement
                                                                                           analysis   and improvement
                                                      plans to lengthen equipment life
                                                                                           techniques
                                                      span and inspection cycles

Organisation & Tidiness Standards in Autonomous Maintenance


FOCUS                                    ELEMENTS

Operator’s responsibility                Organize standards for operator responsibilities;
                                         adhere to them faithfully (including data recording)

Work                                     Promote organized and orderly operations as well as
visual control of work-in-process, products, defects,
                                   wastes and consumables (such as paint)

Dies, jigs and tools               Keep dies, jigs and tools organized and easy to find
                                   through visual control, establish standards for
                                   precision and repair

Measuring instruments and fool- Inventory measuring instruments and fool-proof
proof devices                   devices and make sure they function property;
                                inspect and correct deterioration; set standards for
                                inspection

Equipment precision                Operators must check precision of equipment (as it
                                   influences quality) and standardize procedures


SMALL GROUP ACTIVITIES
Operators and maintenance personnel from small groups and they continue to refine the
inspection process and to generate improvements that increase the equipment life and
effectiveness. They are increasingly involved with maintenance in gathering and analysing
equipment data such as the results of daily inspection, downtime statistics, oil and grease usage,
quality defect data, tool wear records and so on. And they continue to build analytical and
diagnostic stills by working on increasingly challenging improvement projects that reflect cooling
improvement goals, such as reliability and maintainability improvement or quality activities. At
this stage, the operators become full partners in the equipment management process and zero
down time and zero defects become achievable targets.

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Am & sga

  • 1. 5. AUTONOMOUS MAINTENANCE AND SMALL GROUP ACTIVITIES Autonomous Maintenance The principal way in which the production department participates in TPM is through autonomous maintenance- cleaning, inspection, and simple adjustments performed by operators systematically trained through a step-by-step programme. The purpose of an autonomous maintenance program is threefold. First, it brings production and maintenance people together to accomplish a common goal – to stabilize equipment conditions and halt accelerated deterioration. Operators learn to carry out important daily tasks that maintenance personnel rarely have time for. These tasks include cleaning and inspection, lubrication, precision checks, and other light maintenance tasks, including simple replacements and repairs in some environments. Second, an autonomous maintenance program is designed to help operators learn more about how their equipment functions, what common problems can occur and why, and how those problems can be prevented by the early detection and treatment of abnormal conditions. Third, the program prepares operators to be active partners with maintenance and engineering personnel in improving the overall performance and reliability of equipment. Traditionally, the general attitude on the shop floor has been “I run it, you fix it”. Operators were responsible only for setting up workplaces, operating the equipment, and checking the quality of processed work. All management of the equipment’s condition was the responsibility of maintenance staff. By now it should be clear that this way of thinking does not promote optimal equipment performance. The alternatives are sad indeed, because as operators you can easily prevent many breakdowns and quality problems by learning how to recognize abnormal conditions. A great deal of this learning can come about simply through your physical contact with the equipment – by taking a little time to tighten loose bolts, lubricating dry parts and cleaning away dirt, and by noticing dirt or grime on friction surfaces and switches – conditions that can shorten equipment life. While these tasks are easy enough to do, in very few factories are they done well. Often you can find clogged drains, empty oil supply equipment, and other results of neglect. Autonomous maintenance teaches you, the equipment operator, to understand your equipment. Equipment knowledge is no longer limited to operation; now it also includes a lot of things traditionally regarded as maintenance work. This approach is becoming increasingly important as factories introduce more robots and automated systems. Most important, you need the ability to look at the quality of the products and the performance of the equipment and notice when something is not right. This depends on the following three skills: 1. Knowing how to distinguish between normal and abnormal conditions (the ability to establish equipment conditions).
  • 2. 2. Knowing how to ensure that normal equipment conditions are met (the ability to maintain equipment conditions). 3. Knowing how to respond quickly to abnormalities (the ability to restore equipment conditions). When you have mastered all three skills, you will understand the equipment well enough to recognize the causes of future problems. You will realise when the machine is about to produce defects or break down. You will also be able to respond quickly. The following list describes some of the skills operators' need. The ability to detect, correct, and prevent equipment abnormalities and make improvements. This includes understanding the important of 1. Proper lubrication, including correct lubrication methods and methods for checking lubrication. 2. Cleaning (inspection) and proper cleaning methods. 3. Improving equipment to reduce the amount of debris and prevent its accumulation and spread. 4. Improving operation and maintenance procedures to prevent abnormalities and facilitate their prompt detection. The ability to understand equipment functions and mechanisms, and the ability to detect causes of abnormalities. 1. Knowing what to look for when checking mechanisms. 2. Applying the proper criteria for judging abnormalities 3. Understanding the relations between specific causes and abnormalities. 4. Knowing with confidence when the equipment needs to be shut off. 5. Being able to diagnose the causes of some types of failures. The ability to understand the relationship between equipment and quality, and the ability to predict problems in quality and detect their causes 1. Knowing how to conduct a physical analysis of the problem. 2. Understanding the relationship between product quality characteristics and equipment mechanisms and functions. 3. Understanding tolerance ranges for static and dynamic precision, and how to measure such precision. 4. Understanding the causes of quality defects. The ability to make repairs. 1. Ability to replace parts. 2. Understanding of life expectancy of parts. 3. Ability to deduce causes of breakdowns. 4. Ability to take emergency measures. 5. Ability to assist in overhaul repairs. Obviously, anyone who masters all these skills has achieved a very high level indeed, and no one is expected to do hat quickly. Instead, each skill should be studied and practiced for whatever time it takes to acquire proficiency.
  • 3. Implementing Autonomous Maintenance in Seven Steps Table below outlines the seven developmental stages of an autonomous maintenance program. These stages or steps are based on the experiences of many companies that have successfully implemented TPM They represent an optimal division of responsibilities between production and maintenance departments in carrying out maintenance and improvement activities. A Step -by -Step Approach It is very difficult to do several things at the same time. That’s why autonomous maintenance training takes a step-by-step approach, making sure each key skill is thoroughly learned before going on to the next. Autonomous maintenance is implemented in seven steps: Step 1 : Conduct initial cleaning and inspection Step 2 : Eliminate sources of contamination and inaccessible areas. Step 3:Develop and test provisional cleaning, inspection and lubrication standards. Step 4: Conduct general inspection training and develop inspection procedures. Step 5 : Conduct general inspections autonomously. Step 6 : Organise and manage the workplace. Step 7:Ongoing autonomous maintenance and advanced improvement activities.
  • 4. Seven Steps for Developing Autonomous Maintenance Step Activity Goals for Equipment Goals for Group Members (workplace diagnosis) (TPM group diagnosis 1.Conduct Thoroughly remove debris and Eliminate environmental causes Develop curiosity, interest, pride initial contaminants from equipment of deterioration such as dust and and care for equipment through cleaning (remove unused equipment parts) dirt; prevent accelerated frequent contact deterioration Develop leadership skills Eliminate dust and dirt; improve through small group activities quality of inspection and repairs and reduce time required Discover and treat hidden defects 2.Eliminate Eliminate the sources of dirt and Increase inherent reliability of learn equipment improvement sources of debris; improve accessibility of equipment by preventing dust concepts and techniques, while contamination areas that are hard to clean and and other contaminants from implementing small-scale and lubricate; reduce time required for adhering and accumulating improvements inaccessible lubrication and cleaning Enhance maintainability by Learn to participate in areas improving cleaning and improvement through small lubricating group activity Experience the satisfaction of successful improvements 3.Develop Set clear cleaning, lubrication and Maintain basic equipment Understand the meaning and cleaning and inspection standards that can be conditions(deterioration- importance of maintenance by lubrication easily maintained over short preventing activities) cleaning, setting maintaining our own intervals; the time allowed for lubrication, and inspection standards (What is equipment daily/periodic work must be clearly control?) specified Become better team members by taking on more responsibility individually. 4.Conduct Conduct training on inspection Visually inspect major parts of Learn equipment mechanisms, general skills in accordance with the equipment; restore functions, and inspection criteria inspection inspection manuals; find and deterioration;enhance reliability through inspection training, skills training correct minor defects through master inspection skills Facilitate inspection through general inspections;modify innovative methods, such as Learn to perform simple repairs equipment to facilitate inspection serial number plates, colored Leaders enhance leadership skill instruction labels, thermotape through teaching group members gauges and indicators see learn through participation through covers etc. Sort out and study general inspection data; Understand the importance of analyzed data.
  • 5. 5.Conduct Develop and use autonomous Maintain optimal equipment Draw up individual daily and inspection maintenance check sheet conditions once deterioration is periodic check sheets based on autonomously (standardize cleaning, lubrication, restored through general general inspection manual and and inspection standards for ease inspection equipment data and develop of application) autonomous management skills Use innovative visual control systems to make cleaning Learn importance of basic data- lubrication/inspection more recording effective Learn proper operating methods, Review equipment and human signs of abnormality, and factors; clarify abnormal appropriate corrective actions. conditions Implement improvement to make operation easier. 6.Organize Standardize various workplace Review and improve plant Broaden the scope of and manage regulations;improve work layout etc. autonomous maintenance by the workplace effectiveness,product quality, and standardizing various Standardize control of work-in- the safety of the environment management and control items process defective products, dies, Reduce setup and adjustment time; jigs, tools measuring Be conscious of the need to eliminate work-in-prices instruments, material handling improve standards and equipment, aisles, etc. procedures continuously, based Material handling standards on the on a standardization practice and shop floor Implement visual control actual data analysis systems throughout the Collecting and recording data: workplace Managers and supervisors are standardization primarily responsible for Control standards and procedures continuously improving for raw materials, work-in-process, standards and procedures and products, spare parts, dies, jigs, promoting them on the shop and tools floor 7.Carry out Develop company goals; engage in Collect and analyze various Gain heightened awareness of ongoing continuous improvement types of data; improve company goals and costs autonomous activities;improve equipment based equipment to increase reliability, (especially maintenance costs) maintenance on careful recording and regular maintainability and ease of Learn to perform simple repairs and advanced analysis of MTBF operation through training on repair improvement Pinpoint weaknesses in techniques activities equipment based on analysis of Learn data collection and data, implement improvement analysis and improvement plans to lengthen equipment life techniques span and inspection cycles Organisation & Tidiness Standards in Autonomous Maintenance FOCUS ELEMENTS Operator’s responsibility Organize standards for operator responsibilities; adhere to them faithfully (including data recording) Work Promote organized and orderly operations as well as
  • 6. visual control of work-in-process, products, defects, wastes and consumables (such as paint) Dies, jigs and tools Keep dies, jigs and tools organized and easy to find through visual control, establish standards for precision and repair Measuring instruments and fool- Inventory measuring instruments and fool-proof proof devices devices and make sure they function property; inspect and correct deterioration; set standards for inspection Equipment precision Operators must check precision of equipment (as it influences quality) and standardize procedures SMALL GROUP ACTIVITIES Operators and maintenance personnel from small groups and they continue to refine the inspection process and to generate improvements that increase the equipment life and effectiveness. They are increasingly involved with maintenance in gathering and analysing equipment data such as the results of daily inspection, downtime statistics, oil and grease usage, quality defect data, tool wear records and so on. And they continue to build analytical and diagnostic stills by working on increasingly challenging improvement projects that reflect cooling improvement goals, such as reliability and maintainability improvement or quality activities. At this stage, the operators become full partners in the equipment management process and zero down time and zero defects become achievable targets.