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© Lean & Mean Consulting. All rights reserved. 2015© Lean & Mean Consulting. All rights reserved. 2016
12/ 16
Autonomous
M...
World-Class Standards & Best Practices of Operational Excellence
© Lean & Mean Consulting. All rights reserved. 2016
LEAN ...
3
1. Understand the key concepts of TPM and Autonomous
Maintenance activities
2. Learn how to implement the Autonomous Mai...
4
Machine failures have many hidden causes
Failure is what we see
but is only the tip of the
iceberg
Minor machine defects...
5
What is TPM?
Total Productive Maintenance (TPM) is a method to
achieve maximum equipment effectiveness through
employee ...
6
TPM Principles
 Increase Overall Equipment Effectiveness (OEE)
 Upgrade operations and maintenance skills
 Employee i...
7
TPM is a paradigm shift 1
Old Attitude TPM Attitude
I use You maintain &
I fix
Operator Maintenance
We maintain !
Old Philosophy New philosophy
 I operate, you fix, he designs. . .
 Quality is costly. . .
 Supervisors & engineers are...
2
Best Practices and Operational Standards for Operators
Module. 12
10
What is Autonomous Maintenance?
 Autonomous Maintenance is maintenance performed by
operators
 Basic maintenance that...
11
AM is a paradigm shift
Old Attitude TPM Attitude
I use I maintain &
I fix
We maintain
Maintenance Operator MaintenanceO...
12
AM facilitates a culture change
Work Systems
& Processes
Behavior
Attitude
Culture
Changes the way we act…
And the way ...
13
Characteristics of AM Programs
 Organization-led activities
 Supported by company and TPM Promotion Office
 Use of a...
14
Goals of Autonomous Maintenance
Goals of
Autonomous
Maintenance
Prevent
Equipment
Deterioration
Equipment
Restoration &...
15
Natural & Forced Deterioration
 Deterioration is what leads equipment to break down or
generate defective parts
 Natu...
16
Autonomous Maintenance Approach
Source: Adapted from Society for Maintenance & Reliability Professionals
Check
ActPlan
...
3
Best Practices and Operational Standards for Operators
Module. 12
Key Concepts
 Shop-floor based activities
 Operator conducted
 Operator enhancing
 Team activity
 Autonomous Manageme...
19
Activity Board
 Activity board is a visual tool to guide teams to action
 Basic elements of problem solving:
1. What ...
20
Example 3: A.M. Activity Board
Step 2: Sources of Contamination
People Results
Definition
Team Mission
Layout of Line &...
21
Components of an Activity Board
1. Team organization and company’s vision
2. Ongoing results
3. The theme
4. Current si...
22
Activity Board & Daily Standup Meetings
Agenda
• Yesterday’s issues
• Lessons learned
• Manpower status
• Update from t...
23
What is One-Point Lesson?
 One-point lesson is a 5-10 min self-study lesson drawn up by
team members
 Lesson covers a...
24
One-Point Lessons as a Cascading Training Tool
Team members are responsible
for training each other
Teaching promotes e...
25
Types of One-Point Lessons
1. Basic Knowledge
Lesson
2. Examples of Problems 3. Examples of
Improvement
• Training tool...
26
Dept.
Manager
Super-
visor
Team
Leader
Created
by
Basic
Knowledge
Improvement
Example Trouble Cases
Date
Executed
Instr...
4
Best Practices and Operational Standards for Operators
Module. 12
28
7 Steps of Autonomous Maintenance
1. Clean and inspect
2. Eliminate problem sources and inaccessible areas
3. Draw up c...
29
Step 1 – Clean and inspect
 Eliminate all dirt and grime on the machine, lubricate and
tighten bolts
 Find and correc...
30
Initial Cleaning is the Foundation of
Autonomous Maintenance
 Cleaning is inspection
 Inspection is finding problems
...
31
When You Find a Problem, Tag It!
 Attach a tag to each problem you expose so that it won’t be
forgotten
 Fix problems...
32
Step 2 – Eliminate problem sources and
inaccessible areas
 Correct sources of dirt and grime
 Prevent spattering
 Im...
33
Step 4 – Conduct general inspections
 How to develop general inspection
 Overall inspection procedures and sub-steps
...
 Lubrication
• Color-coded marks to indicate
oil inlets
• Oil level and supply interval
labels
• Indication of upper and ...
35
Example: Use of Match Marks
Match marks are placed
on bolts and nuts so that
operator can easily detect
if bolts have b...
36
Step 5 – Conduct autonomous inspections
 Prepare standard check sheets for autonomous inspections
 Define autonomous ...
37
Checklist for Daily Operator PM
 1. Check coolant level through clear Plexiglas
 2. Check heat exchanger fans
(string...
5
Best Practices and Operational Standards for Operators
Module. 12
39
How to Sustain AM?
 Active leadership for TPM initiative
 AM is owned by Production department and supported by
Maint...
40© Lean & Mean Consulting. All rights reserved. 2016
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Autonomous maintenance preview

Autonomous Maintenance (AM) is dedicated to Operators. It is a great idea of TPM strategy to make operators directly involved in improving machines availability and enhancing TPM overall efficiency. Since “Total” means the involvement of all and everybody in a continuous improvement and waste elimination (MUDA), the role of Maintenance evolves from reactive to preventive, and most of the daily inspections are shifted to operators.

In short, a new definition of the roles in Maintenance means that technicians and engineers focus on preventive & predictive maintenance, while production operators do the autonomous maintenance. Technicians are obliged to deal with breakdowns and restore the production, while operators are involved in eliminating micro-stoppages. Since both parties know well their machinery and equipment, the list of AM activities should arise from their common experience.
Finally, operators need to be well trained and then they can be provided with checklists to perform the tasks assigned.
This module of LEAN Academy will tell us that there are two levels of AM: level 1 – routine checks, and level 2 – specific actions e.g. lubrication, replacement of parts, cleaning etc.

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Autonomous maintenance preview

  1. 1. © Lean & Mean Consulting. All rights reserved. 2015© Lean & Mean Consulting. All rights reserved. 2016 12/ 16 Autonomous Maintenance Best Practices and Operational Standards for Operators World-Class Standards & Best Practices of Operational Excellence
  2. 2. 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
  3. 3. 3 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
  4. 4. 4 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
  5. 5. 5 What is TPM? Total Productive Maintenance (TPM) is a method to achieve maximum equipment effectiveness through employee involvement Management + Operators + Maintenance
  6. 6. 6 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
  7. 7. 7 TPM is a paradigm shift 1 Old Attitude TPM Attitude I use You maintain & I fix Operator Maintenance We maintain !
  8. 8. 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
  9. 9. 2 Best Practices and Operational Standards for Operators Module. 12
  10. 10. 10 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
  11. 11. 11 AM is a paradigm shift Old Attitude TPM Attitude I use I maintain & I fix We maintain Maintenance Operator MaintenanceOperator
  12. 12. 12 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…
  13. 13. 13 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
  14. 14. 14 Goals of Autonomous Maintenance Goals of Autonomous Maintenance Prevent Equipment Deterioration Equipment Restoration & Proper Management Establish Basic Conditions
  15. 15. 15 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
  16. 16. 16 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
  17. 17. 3 Best Practices and Operational Standards for Operators Module. 12
  18. 18. 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
  19. 19. 19 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)
  20. 20. 20 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
  21. 21. 21 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
  22. 22. 22 Activity Board & Daily Standup Meetings Agenda • Yesterday’s issues • Lessons learned • Manpower status • Update from top management • Lean/TPM activities • Today’s target & actions
  23. 23. 23 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
  24. 24. 24 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
  25. 25. 25 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
  26. 26. 26 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 1 2 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
  27. 27. 4 Best Practices and Operational Standards for Operators Module. 12
  28. 28. 28 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
  29. 29. 29 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
  30. 30. 30 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
  31. 31. 31 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
  32. 32. 32 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.
  33. 33. 33 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
  34. 34.  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
  35. 35. 35 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.
  36. 36. 36 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.
  37. 37. 37 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
  38. 38. 5 Best Practices and Operational Standards for Operators Module. 12
  39. 39. 39 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
  40. 40. 40© Lean & Mean Consulting. All rights reserved. 2016

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