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© Lean & Mean Consulting. All rights reserved. 2015© Lean & Mean Consulting. All rights reserved. 2016
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Autonomous
Maintenance
Best Practices and Operational Standards for
Operators
World-Class Standards & Best Practices of Operational Excellence

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World-Class Standards & Best Practices of Operational Excellence
© Lean & Mean Consulting. All rights reserved. 2016
LEAN Management Academy - Outline
Knowledge & Expertise / Editable Training Presentations / 16 Modules

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1. Understand the key concepts of TPM and Autonomous
Maintenance activities
2. Learn how to implement the Autonomous Maintenance
activities, step by step
3. Learn how to use activity boards, meetings and one-point
lessons to promote TPM goals
4. Understand the critical success factors in sustaining
Autonomous Maintenance activities on the shop-floor
Learning Objectives

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Machine failures have many hidden causes
Failure is what we see
but is only the tip of the
iceberg
Minor machine defects are
generally unnoticed but are
the cause of almost all
machine failures
Loosening
Contamination
Corrosion
Leaks
Flaws
Deformation
Vibration
Cracks Backlash
Improper Temperature
Wear
Failure
Visible
Less
Visible

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What is TPM?
Total Productive Maintenance (TPM) is a method to
achieve maximum equipment effectiveness through
employee involvement
Management + Operators + Maintenance

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TPM Principles
 Increase Overall Equipment Effectiveness (OEE)
 Upgrade operations and maintenance skills
 Employee involvement through small group activities
 A fact-based approach to continuous improvement

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TPM is a paradigm shift 1
Old Attitude TPM Attitude
I use You maintain &
I fix
Operator Maintenance
We maintain !

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Old Philosophy New philosophy
 I operate, you fix, he designs. . .
 Quality is costly. . .
 Supervisors & engineers are
experts. . .
 Defects, speed losses & unplanned
downtime are inevitable…
 Inventory is useful
We are all responsible for our
equipment.
Quality is free.
Operators/Maintenance are
experts too.
Zero defects, zero speed losses,
zero unplanned downtime.
Inventory is costly.
TPM is a paradigm shift 2

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Best Practices and Operational Standards for Operators
Module. 12

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What is Autonomous Maintenance?
 Autonomous Maintenance is maintenance performed by
operators
 Basic maintenance that can be easily performed on a daily
basis, e.g. inspection, cleaning, lubrication, etc.
 Learning about the equipment to understand how it works
and be able to spot signs of trouble
 An employee engagement program as part of the Lean/TPM
initiative

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AM is a paradigm shift
Old Attitude TPM Attitude
I use I maintain &
I fix
We maintain
Maintenance Operator MaintenanceOperator

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AM facilitates a culture change
Work Systems
& Processes
Behavior
Attitude
Culture
Changes the way we act…
And the way we think…
By improving equipment and processes…

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Characteristics of AM Programs
 Organization-led activities
 Supported by company and TPM Promotion Office
 Use of audits
 Determine full implementation of each step
 Provide feedback on strengths and weaknesses
 Clarify what needs to be achieved and best way to do it
 Use of Activity Boards
 Meeting and reports

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Goals of Autonomous Maintenance
Goals of
Autonomous
Maintenance
Prevent
Equipment
Deterioration
Equipment
Restoration &
Proper
Management
Establish Basic
Conditions

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Natural & Forced Deterioration
 Deterioration is what leads equipment to break down or
generate defective parts
 Natural Deterioration – Normal wear caused by parts rubbing
against one another
 Forced Deterioration – Deterioration that happens sooner
than it would naturally. Usually caused by our failure to do
something we ought to. Examples:
 Not keeping parts clean and lubricated
 Ignoring excessive loads in moving parts

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Autonomous Maintenance Approach
Source: Adapted from Society for Maintenance & Reliability Professionals
Check
ActPlan
Do
Examine &
expose problems
Counter &
solve problems
Execute & follow
standards & rules
Prevent recurrence
through improvement

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Best Practices and Operational Standards for Operators
Module. 12

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Key Concepts
 Shop-floor based activities
 Operator conducted
 Operator enhancing
 Team activity
 Autonomous Management
 TPM Foundation
 Part of the job!
3 Key Tools
 Activity Board
 Meetings
 One Point Lessons

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Activity Board
 Activity board is a visual tool to guide teams to action
 Basic elements of problem solving:
1. What are we going to do? (Theme)
2. Why are we going to do it? (Vision)
3. How far are we going to go? (Targets)
4. How are we going to do it? (Method)
5. What is the sequence and timing of actions? (Schedule)
6. Who does what? ( Roles)
7. What results do we expect? (Assessment)

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Example 3: A.M. Activity Board
Step 2: Sources of Contamination
People Results
Definition
Team Mission
Layout of Line &
Identified Important Areas
Safety Hazard
Contamination
Hard-to-reach
Main Failure
• Team Name
• Members
Line
• Mission
• Objectives
Activity & Findings
Step 1: Initial Cleaning
Pictures Before After
Tag List Production Maintenance
Tag Movement
Actual Tags
Display actual findings from
Initial Cleaning such as trash,
unnecessary items, dust and
other contamination
Explain and show Focused
Improvement activities
for sources of contamination
One-Point-Lessons
Team

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Components of an Activity Board
1. Team organization and company’s vision
2. Ongoing results
3. The theme
4. Current situation and causes
5. Actions to address the causes
6. Log of targets achieved, remaining problems and actions
planned to resolved them

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Activity Board & Daily Standup Meetings
Agenda
• Yesterday’s issues
• Lessons learned
• Manpower status
• Update from top management
• Lean/TPM activities
• Today’s target & actions

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What is One-Point Lesson?
 One-point lesson is a 5-10 min self-study lesson drawn up by
team members
 Lesson covers a single aspect of equipment or machine
structure, functioning, cleaning, lubrication, inspection or
tightening method
 Is a highly effective tool because it is short and focused on a
topic

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One-Point Lessons as a Cascading Training Tool
Team members are responsible
for training each other
Teaching promotes effective
leadership and accountability
One-point lessons – a teaching
tool that is short and to the point
Follow up to see what has been
taught is practiced

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Types of One-Point Lessons
1. Basic Knowledge
Lesson
2. Examples of Problems 3. Examples of
Improvement
• Training tool designed to
fill in knowledge gaps
• To ensure team members
have consistent
knowledge they need for
daily production and
TPM activities
• Lessons are focused on
equipment subsystems,
safety points, or basic
operating information
• Based on problems that
have already occurred,
these lessons are
designed to
communicate knowledge
or skills to help operators
prevent similar problems
from happening in the
future
• To ensure that successful
improvement ideas are
used widely, these
lessons present what
needs to be done to
prevent or correct
equipment abnormalities
• It describes the
approaches, actions, and
results of specific
improvement projects

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Dept.
Manager
Super-
visor
Team
Leader
Created
by
Basic
Knowledge
Improvement
Example Trouble Cases
Date
Executed
Instructor
Subject
Compressed Air Usage
For Line #1 & 2
TPM One-Point Lesson
No.
Date of
Creation
November, 2010
DL4301
David
Classification
Tom
ActionHistory
Mark Paul
1. Compressed Air
may only be used on
the Dribbler Scale
ONLY
2. Scale Area is
currently Hard-To-
Reach and may cause
variable weight if not
cleaned
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Don’t Make A Bigger Mess !!!
Example: One-Point Lesson
One-Point Lesson is a tool
with the following
characteristics:
One sheet…
To share the results
of autonomous study…
For 5-10 minutes
Contents can be knowledge and
skills of:
Equipment
Safety
Operation process
Task

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Best Practices and Operational Standards for Operators
Module. 12

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7 Steps of Autonomous Maintenance
1. Clean and inspect
2. Eliminate problem sources and inaccessible areas
3. Draw up cleaning and lubricating standards
4. Conduct general inspections
5. Conduct autonomous inspections
6. Standardize through visual workplace management
7. Implement autonomous equipment management
Source: Autonomous Maintenance for Operators by JIPM

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Step 1 – Clean and inspect
 Eliminate all dirt and grime on the machine, lubricate and
tighten bolts
 Find and correct problems
 Implement the Activity Board and the 4Ms
 Address operators’ questions during education process
 Develop countermeasures to mis-operations as early as
possible
Eliminate all sources of dirt and grime on the machine,
lubricate, tighten bolts, and find and correct problems

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Initial Cleaning is the Foundation of
Autonomous Maintenance
 Cleaning is inspection
 Inspection is finding problems
 Problems demand restoration to original proper conditions
and improvement to prevent recurrence

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When You Find a Problem, Tag It!
 Attach a tag to each problem you expose so that it won’t be
forgotten
 Fix problems as soon as possible and remove the tag
 Draw up plans for resolving problems that can’t be addressed
immediately

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Step 2 – Eliminate problem sources and
inaccessible areas
 Correct sources of dirt and grime
 Prevent spattering
 Improve accessibility for cleaning and lubrication
 Establish time targets for cleaning
 Establish tentative standards
Correct sources of dirt and grime; prevent spattering and
improve accessibility for cleaning and lubrication. Shorten the
time it takes to clean and lubricate.

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Step 4 – Conduct general inspections
 How to develop general inspection
 Overall inspection procedures and sub-steps
 Preparing inspection education
 Conducting overall inspection education
 Set tentative inspecting standards
 Restore and improve equipment

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 Lubrication
• Color-coded marks to indicate
oil inlets
• Oil level and supply interval
labels
• Indication of upper and lower
oil level limits
• Indication of oil consumption
per standard time unit
• Color-coding on oil cans to
indicate oil types
 Equipment elements
• “Inspected” marks and math
marks
• Color-coding (blue) on bolts
reserved for adjustment by
maintenance personnel only
• Color-coding (yellow) on holes
that do not require bolts
Suggestions for Visual Controls

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Example: Use of Match Marks
Match marks are placed
on bolts and nuts so that
operator can easily detect
if bolts have been loosen
due to excessive
vibrations. These are
being placed on critical
bolts after each bolt had
received their correct
torque.

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Step 5 – Conduct autonomous inspections
 Prepare standard check sheets for autonomous inspections
 Define autonomous chart / schedule for each operator
 Carry out the inspections
 Use new methods of cleaning and lubricating
Prepare standard worksheets for autonomous
inspections. Carry out the inspections.

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Checklist for Daily Operator PM
 1. Check coolant level through clear Plexiglas
 2. Check heat exchanger fans
(strings should be moving)
 3. Check servo drive fans
(string should be moving)
 4. Check heat exchanger air filter
(change when dark)
 5. Check servo drive air filter
(change when dark)
 6. Check way lube reservoir
(add when low)
 7. Check main motor air filter
(change when dark)
 8. Check main motor cooling fan
(string should move)
 9. Check mist collector motor and air filter
(change when dark)
 10. Check bar feeder hydraulic motor air filter
 11. Check bar feeder hydraulic oil level
(add when low)
Example: Checklist for autonomous
inspections

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Best Practices and Operational Standards for Operators
Module. 12

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How to Sustain AM?
 Active leadership for TPM initiative
 AM is owned by Production department and supported by
Maintenance department
 Proper operator training, education and skills certification
 The time required for cleaning and lubrication must be
included in the daily schedule
 Supervisors need to ensure that AM activities are performed

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40© Lean & Mean Consulting. All rights reserved. 2016