Assisting Operations to maintain its own equipment

1. Autonomous Maintenance Assisting the Operations to maintain its own equipment Anand Subramaniam

2. 2 “Automatic simply means that you can't repair it yourself.” - Mary H. Waldrip

3. 3 Highlights Maintenance Types Autonomous Maintenance

4. Maintenance Types

6. Classification

7. Criticality

9. Technical

10. Manuals

11. Drawings

13. Services

14. Facilities

15. Equipment

17. Scheduling

19. Communication

20. Structure

21. Support

23. Reports

24. Tracking

27. Tool Breakdown

29. Correct problem

30. Set up Machine to make good parts

32. Problem Solving Tools

33. Vibration Analysis Tools Reliability Maintenance

35. Product

36. Operation

37. Reputation

38. Profitability

39. Customers

40. Employees involvement

42. Provide redundancy

43. Improve individual components

44. Maintenance

45. Increase repair capabilities

47. Planned Maintenance Transition 10

48. Maintenance Prevention Life Cycle Costing Assembly at Supplier Input from Kaizen activities Input from Reliability Maintenance Input from Preventative Maintenance Design reviews (Operators, Supervisors, Engineers) Final Inspection at Supplier Maintenance and Operations Manual preparation Safety Issues visible, aware and worked Preventative Maintenance Schedule posted, adhered to New equipment design integrated with New Product Introduction (NPI) efforts 11

49. Autonomous Maintenance

50. Definition Operations maintains its own equipment Utilise 7-step plan* (*Source: Japan Institute of Plant Maintenance - JIPM) 13

51. Seven Steps to TPM 14 Autonomous Management 7 6 5 4 3 2 1 Aut. Mgt. 7 Orderliness & Tidiness 6 Autonomous Cleanup 5 Overall Checkup (Internal) 4 Initial Standards Formulation 3 Stop Sources of defects (External) 2 Starts with 6S Initial Clean-up (External) 1

52. Step 1 – Initial Clean-up (External) Kick-off” program Closely aligned with 6S (5S + 1) Management and Staff show commitment Clean, Sand and Paint Identify sources of defects Gauge hidden Limit switch buried in debris Crack in Housing 15

53. Step 2 – Stop Sources of Defects (External) Ask ‘why ?’ five times Replace parts with cracks or worn seals Teach Operators how to modify equipment Conduct Set-up Workshops & Practice Modify Equipment for easier checking and to eliminate sources for debris and contamination Guards Chip removal Acrylic covers to see V - belts and moving parts 16

54. Step 3 – Initial Standards Formulation Standards for clean-up and checking What equipment should be cleaned and checked? What points should be checked? Who should check? What check sheet should be used? How to react to changes. Standards are to capture what has been learned in steps 1 and 2 17

55. Step 4 – Overall Checkup (Internal) Leaders (1st line Supervisors) trained Hydraulics Air Pressure Electrical/ Electronics Lubrication Mechanical One point lessons developed (Visual Management) Team up Engineers, Maintenance, and Operators Tear down equipment Analyse defects Present findings 18

56. Step 5 – Autonomous Checkup Develop Standards for routine internal checkup Hydraulics Air Pressure Electrical/ Electronics Lubrication Mechanical Operator executes routine checks 19

57. Step 6 – Orderliness and Tidiness Improve on Supplier Activity Spare parts supply partners Spare parts stores Spare parts inventory Improve on Tool Activity Tool Crib orderliness Tools frequently used at work station (refer to Visual Management / Visual Control) 20

58. Step 7 – Autonomous Management Process never ends Metrics Audits Each process post Results (actual) against Goal (target) Zero lost time accidents Zero Defects Zero Breakdowns Zero set-up time or at least < 10 minutes 21

59. 22 “The major difference between a thing that might go wrong and a thing that cannot possibly go wrong is that when a thing that cannot possibly go wrong goes wrong it usually turns out to be impossible to get at or repair.” - Douglas Adams

60. 23 Good Luck http://www.linkedin.com/in/anandsubramaniam