We are facing Below mentioned issue on M- 1& M-3 Lines since from long time 1) The Mussing PLC goes in holt mode at the time of starting the cell. It will take few minutes to restart after repeatedly switching on – off. at the beginning of shift This problem is savior at two places waz . Down tube and Steering Head. ( M-1 Line) It is risky from maintenance point of view & there are chances of damaging the PLC permanently As the Messung has windup their business spares parts management is also a headache for us . As per discussion with my team members and consequently with you in present scenario we have to replace the Messung PLC by Mitsubishi PLC ( like Installed on M-2 Line) is the only alternative. I am preparing the action plan for same with my team. But we need your valuable technical support in this case. Once the management approves budget and according to production planning we can work out for micro level plan. Waiting for your support and guidelines. JH ACTIVITES

1. TOTAL PRODUCTIVE MAINTENANCE

2. Total Productive Maintenance
• Total
Total participation - everybody is involved
Total machine
Total life cost of ownership
Total effectiveness
• Productive
Optimal equipment conditions for Production
Optimal maintenance-process Performance
• Maintenance
Maintenance Prevention
Improved Maintainability
Preventative Maintenance
Moving from the old attitude “I operate it and you fix it!” to the new attitude “We are all responsible
for our equipment!”

3. Goals and Activities of TPM

5. The 3 Principles of TPM...
1) Detection: Using preventive and predictive technologies to
inspect, detect and then correct small defects before they can
become costly repairs
2) Restoration: Restoring equipment to optimal conditions
3) Prevention: Preventing small defects from becoming major
problems by correcting them before they become costly
repairs

7. Types of Maintenance
 Maintenance Prevention - designing or selecting equipment that will run with minimal maintenance and is
easy to service when necessary.
 Predictive Maintenance - determining the life expectancy of components in order to replace them at the
optimum time.
 Autonomous Maintenance - involving production employees in the total machine maintenance process.
Goes with 5S well.
 Preventive Maintenance - using schedules or planned maintenance to ensure the continuous, smooth
operation of equipment.
 Systematical Preventive Maintenance : tasks to be systematically performed on schedule
 Conditional Preventive Maintenance : tasks to be performed or not after scheduled checking
 Corrective/Reactive Maintenance - Fixing an existing equipment when it breaks or looses its original
performance

9. Breakdown Frequency VS Breakdown Lead Time
Autonomous Maintenance
Corrective  Preventive Maintenance

10. AUTONOMOUS MANAGEMENT

11. Autonomous Management
• Definition : Direct participation of production operators in the
management of the machine through daily check, lubrication, early
detection of abnormalities, replacement of parts or small repair.
• Is the system to re-educate ourselves whilst restoring and improving
our machines :
• Developing our people and enabling them to take care of their
machines
• Influencing of the personal attitudes, value and behaviors of our
employee to continually enhance the condition in which they
work
• Creating the base and the resource for performance improvement
Through AM We change our people and machines !!

12. Autonomous Management : Definition
12
SHARED RESPONSIBILITY OF MAINTAINING ”BASIC CONDITIONS” OF
EQUIPMENT BETWEEN PRODUCTION AND MAINTENANCE
 Daily/Time-Based Maintenance
– Cleaning
– Lubrication
– Tightening
 Daily inspection by using 5 SENSES
 Right operation, right adjustment, right setting
“I operate, You fix.” “We are AlI responsible for
Our equipment.”
“I operate, You Clean.” “We are AlI responsible for
cleanliness of Our line.”
Pillar II : Autonomous Maintenance

13. Why Autonomous management necessary and
which skill are required by operators?

14. What are the expected result of Autonomous
Management implementation?

15. 15
Available Time = 100 % OEE
Operating Time
Valued
Operating
Time =
25 % OEE
Downtime
Net
Operating
Time Performance
Quality
1. Equipment Stop Loss  Pallet
Jams, Silo stops, Slide Gate, etc
2. Set up/Adjustment Loss  Sensor
Dirty / Off, Adjust Former height, etc
3. Parts Change Out  Leaky cylinder,
Change Over Loss, Wait System,
4. Start Up Loss  Change Overs,
Not ready at 4AM,12 Noon, 8PM
5. Minor Stoppage Loss  Lack of ***
Dribbler adjustments, Bags jamming
6. Speed Loss  Run Rate, Machine
Speed – Conveyor Belts, Dribbler,etc
7. Defect/Rework Loss  Bad formula,
Wrong ingredients, On hold, etc
Wasted$$’s

16. 3 Key Tools for Autonomous Management
Key Concepts
• Shop floor based
activities
• Operator conducted
• Operator enhancing
• Team activity
• Autonomous
Management
• TPM Foundation
• Part of the job!
16
3 Key Tools
 Activity Board
 Meetings
 One Point Lessons

17. 17
Example of A.M. Activity Board
People Treasures
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.
Step 2: Sources of Contamination
Explain and show Focused
Improvement activities
for sources of contamination
One-Point-Lessons
Team

18. 18
Dept. / Line : Bldg Y Mach. ID : Date: 4/28/2004
S D W M
Cleaning
1 Water trap Empty bowl Open valve Cloth 1 X Operator
This is the maximum level for water in the bowl.
Open valve at bottom to release water, wipe up with clean cloth.
Insert
Picture
Here
Tools
T
(Min)
Person
Resp.
Autonomous Maintenance
Routine Cleaning, Inspection, & Lubrication Standard
Freq
Diagram No. Item Criterion Method
Area : Bag Printer Tag # :

19. One Point Lessons
Dept.
Manager
Super-
visor
Team
Leader
Created
by
Basic
Knowledge
Improvement
Example
Trouble
Cases
Date
Executed
Instructor
Trainee
Daniel
Classification
John
Action
History
Subject
Compressed Air Usage
For Line #1 & 2
TPM One-Point Lesson
No.
Date of
Creation
November, 2003
DL1034
Jerry 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
1
2
Don’t Make A Bigger Mess !!!
19
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

20. The Five S
The Five Steps of Housekeeping
1. Sort: Separate out all that is unnecessary and eliminate it.
2. Store: Put essential things in order so they can be easily accessed.
Everything has a place… and is in its place. And visual
management.
3. Shine: Clean everything – tools and workplaces – removing stains,
spots, debris and eradicating sources of dirt. Bring everything to
“NEW” and better than new.
4. Standardize: Standardize the previous three steps to make the
process one that never ends and can be improved upon.
5. Sustain: Make cleaning and checking routine.
20

21. 21
SERVICING
ACTIVITIES
REPAIR
MAINTENANCE
PREDICTIVE
MAINTENANCE
PREVENTIVE
MAINTENANCE
ROUTINE
MAINTENANCE
ROBUSTNESS IMPROVEMENT
EFFECTIVE AND APPROPRIATE REPAIRS
TRENDS MEASURE AND CONTROL
NOT TIME BASED SERVICING
BUILDING OF PROGRAMS
TIME BASED APPLICATIONS
CLEANING- REFURBISHING
GREASING-SCREWING
DAILY INSPECTION
DAILY EQUIPMENT CARE
X
X
X
X
X
X X
X
X
X
X
Mfg Maint
WHO DOES WHAT ?

22. The 7 steps of Autonomous Maintenance
22
1. Initial Cleaning
(Initial Inspection &
“Restoration”)
2. Source of Contamination
& Hard-to-Reach areas
3. Standards of Cleaning
& Lubrication
4. General Inspection
5. Autonomous Inspection
6. Standardize Autonomous
Maintenance operations
7. Autonomous
Management
-Detect problems of lines and restore its original state.
-Start managing the line autonomously.
( 5S, Minor Stops, Quality )
-Create & perform temporary
“Cleaning/Lubrication procedures.”
-Solve “Sources of Contamination” and
“Hard to Reach” areas. (Cleaning, Inspection, Lubrication)
-Develop tentative standards for cleaning, lubrication and
inspection.
-Provide training on their equipments, products and
materials, inspection skills and other AM skills.
Develop a routine maintenance standard by operators
Standardize routine operations related to workplace
management such as quality inspection of products,
life cycle of jigs, tools, set up operation and safety.
Autonomous team working

23. 3 Phases of Autonomous Management
Phase 1
2. Source of
contamination & Hard to
Clean
3. Standard of Cleaning &
Lubrication
4. General Inspection 5. Autonomous Inspection
1. Initial
Cleaning
Phase 2
6. Standardize
Autonomous Maintenance
Operation
7. Autonomous
Management
Phase 3

24. Target of initial cleaning :
Phase 1
1. Initial Cleaning

25. What to detect during Initial Cleaning? “Categories of Abnormality”
S: Safety Items : safety area, spot, work environment
1: 5 S Related (Unnecessary) Items:
 Sort: Unnecessary items
 Store: Disorganized storage, Lack of Visual Indications
 Shine: Cleanliness/Preserve
2: Sources of Contamination:
 Leaks, Spills
3: Hard-to-Reach area
4: Minor Defect
 Contamination
 Broken Parts
 Looseness
 Abnormal Function
 Adession
5: “Basic Conditions”:
 Lubrication
 Tightening
 Cleaning & Inspection
6: Quality Related: Causes of defect
25
Phase 1

26. 26
Before After
Phase 1

27. F-Tagging
27
During
Initial Cleaning
Afterwards –
Every Day Process
Phase 1

28. Tagging should be a continuous activity
Phase 1

29. Monitoring Tags
• Initial Cleaning is not an one time event. It should be repeated monthly.
• The more restoration you continue, the less Initial Cleaning time you will
need.
0
50
100
150
200
250
I
n
i
t
i
a
l
C
l
e
a
n
i
n
g
(
J
u
n
e
)
J
u
l
y
A
u
g
u
s
t
S
e
p
t
e
m
b
e
r
O
c
t
o
b
e
r
N
o
v
o
m
b
e
r
D
e
c
e
m
b
e
r
Number
of
Tags
29
Tag Issued
Tag
Restored
Phase 1

30. Phase 1

31. Major Impact from Initial Cleaning Activity
• 10 % increase in Machine Time by cleaning and adjustment of cylinders
and air tubes of Bag Former
(13 cycle/min to 15 cycle/min)
31
Phase 1

32. Target
Phase 1
2. Source of contamination & Hard to Clean

33. Modify Hard to Clean Parts
Phase 1

34. Make Hidden Inspection Points Are Visible
Phase 1

35. The best cleanliness are no need to clean !!
Phase 1

36. Target :
Phase 1
3. Standard of Cleaning & Lubrication

37. Phase 1

38. Phase 1

39. Phase 1

40. Phase 2
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