1. Autonomous
Maintenance
ZB - 20140721
Steven Wigglesworth
Pillar Introduction

2. 2
LeanTPM AM Pillar
Aim…
Purpose of this Introduction
To describe Autonomous Maintenance pillar
and how it is embedded within our LeanTPM
program

3. 3
Autonomous Maintenance
AM Pillar - Why, What and How …
Why AM
To enable loss focused improvement in relation to machine and process
owned by the operator. With a measurable effect on reliability through
safety, performance & product quality. This approach is an operator
capability building system, with the development of defined cleaning &
hygiene standards for optimal machine conditions.
What to do
Start by selecting pilot area and align the pilot approach with first the
quality of implementation and success when delivered. Make an
expansion plan to other areas (loss focussed) and ensure standards have
equally high expectations and people capability is at the forefront.
How to do it
From pilot (AM – Fundamental scope) ensure we train, support and coach
the teams to get the wins and trust that we need. We must first prove the
pilot works and that the implementation is considered and structured in a
way that gains momentum. Then pillar is ready to be launched following
CSC LeanTPM framework.

4. 4
LeanFlow
LeanTPM 1001
Sustainable continuous improvement
LeanTPM Fundamentals
AutonomousMaintenance
ProductiveMaintenance
Training&Development
Focussed Improvement Pillar
Aim is to enable continuous improvement process; driving,
recording and sustaining team improvement efforts centred around
loss/waste elimination to maximize the overall effectiveness of
equipment and processes
Autonomous Maintenance Pillar
Aim of AM is to minimise short stops, changeovers & support
breakdowns reduction by maintaining equipment in optimal
condition. AM pillar can/should be used to address mentioned
losses based on the loss in focus (Identified by FI Pillar)
Productive Maintenance Pillar
Aim of PM is to achieve reliable equipment with zero unforeseen
breakdowns and decrease to planned stoppages. PM pillar must
address losses and develop the systemised approach
FocussedImprovement
Training & Development Pillar
Aim is to build capability and to eliminate losses due to lack of
skills. T&D pillar support pillars with development of needed skills
to ensure pillar activates and to hold the gains
LeanFlow Pillar
Aim is To stabilize & simplify value stream processes reducing complexity
and minimizing leadtime in order to achieve flow and flexibility. The
ultimate aim of this pillar is to shift from current classical silo thinking to
customer driven organization thinking
Autonomous Maintenance
A fundamental which becomes a pillar …
Autonomous maintenance fundamental must be piloted first if is to be successful. Following
pilot it can be mature and launched as a pillar approach.

5. 5
Autonomous Maintenance
AM Steps – Why, What and how….
Steps Why
Step 0 – Preparation
Step 2 –Eliminate difficult to
clean and inspect areas
Step 1 –Initial cleaning (Build
cleaning and inspection system)
Step 3 – Create & maintain
CIL standards
Step 4 – General Inspection
Step 5 – Autonomous Inspection
Step 6 – Standardisation
Step 7 – Autonomous
Management
What How
Make risks and
process understood
Identify risks hazards for
countermeasures and
understand basic processes
Map the machine process for
education and identify where
injury could occur how and why
Defining preliminary
tasks from which we
can improve
Be able to identify the
normal from abnormal
Develop initial cleaning &
inspection tasks and measure
for basic target conditions.
Eliminate issues &
tasks or simplify for
reduced impact.
Identify issue causes &
improvement areas
Develop improvement
objectives to reduce difficulty
in maintaining standard
Create a standard
hold the gains
Standardise work for
cleaning, inspection &
lubrication.
Use standard cleaning,
inspection & lubrication &
process confirm.
Increase capability
and transfer of
inspection
Divide common failures types
of components into inspection
opportunities train & verify
Up-skill operator at
component level
Improve time for
inspection – reduce
static maintenance
Implement deeper
inspection criteria and
simplify into standard work
Conclude transfer of
inspections from maintenance
teams and simplify.
To improve further
reducing waste and
loss
Create work place flow for
inspection and
maintenance
Map materials and tools for
reduction in motion,
transportation losses.
Enable & encourage
operators to own the
system
Create the operator team
management system
Develop unit approach with
operators - knowing their
process & machine standard.

6. Use the phases to realise
zero waste / loss
Phase 2
Improve
Phase 3
Continuously Improve
Phase 1
Restore - Stabilize

7. 7
Autonomous Maintenance
Losses reduction, AM Steps main activities…
Based on
component
failures – up-
skilling of
operators
component
knowledge
0-3 4 5 6 7AM Pillar steps
How
Whole machine focus initially at
outset for restoration – then link
with ABC of critically of
equipment for results
Consolidate
inspections
and ease to
complete,
introduce
quality
points
Make flow of tools
and materials
optimal as
possible
Operator
unit
approach –
“their
process and
equipment”
Restore - Stabilize Improve Continuous Imp.
Phase1 Phase 2 Phase 3
AM Pilot 0-3
5S Pilot 1-5
Fundamental pilots before pillar expansion

8. Equipment
performance
Capacity loss
Material and
energy
efficiency
Workplace
efficiency
8
Reduced speed FI AM / PM / PQ / LeanFlow / T&D
Change over time AM PM / FI / LFlow / T&D
Start-up time/Set up FI AM / PM / PQ / LeanFlow / T&D
External reasons FI PM / AM / T&D
Preventive Maint. during prod. time AM / FI / T&DPM
Breakdown losses AM / FI / T&DPM
Short stops AM FI / PM / T&D
Cleaning Time AM PM / PQ / EHS / FI / LFlow / T&D
Defect and Re-work PQ* FI / PM / AM / LeanFlow / T&D
Productive waste LeanFlow FI / AM / OA / EHS / T&D
Capability waste T&D FI / LeanFlow / T&D
Quality waste PQ* FI / LeanFlow / T&D
Raw - & Packaging material FI PM / PQ / EHS / AM / LFlow / T&D
Consumables FI PM / PQ / EHS / AM / LFlow / T&D
Utilities loss EHS* FI / PM / AM / LeanFlow / T&D
No production order LeanFlow FI / PM / T&D
Maintenance overhaul PM FI / T&D
Capex modifications/installations EEM* FI / PM / AM / LeanFlow / T&D
Loss and waste Accountable Support
*PQ,EEM,OA,EHS–currentlynotactive
Autonomous Maintenance
Losses reduction ownership…