Autonomous Maintenance

Transcription

1 Autonomous Maintenance Focussed Improvement Effective Maintenance Education and Training Early Management Quality Maintenance TPM in Administration Safety, Health, Environmental Total productive Maintenance Autonomous Maintenance 5 S - Step 0

2 Introduction Total Productive Maintenance Definition: A structured approach that establishes a corporate culture, that will maximise production system effectiveness TPM: Total Involvement of all functions and people at all levels of organisation Productive Efficient and effective utilisation of all resources Maintenance Keeping the manmachine-material system in optimal condition Aim of TPM: Prevent losses and achieve: Zero Accidents Zero defects Zero Breakdowns in the entire production system life

3 Introduction Autonomous Maintenance Autonomous according to the dictionary means independent, self-sufficient or self-governing AM is the foundation stone of TPM Activities by Operators to create & maintain base conditions for optimal operation. Without operators who can look after their own machines, losses and break-downs cannot be reduced. It is a way to secure improvements. I am in charge of my machine

4 Objective Problems that stop or slow the machine can be eliminated by changing the attitude of the people Managers, Operators & Technicians In other words Zero Defect & Zero Breakdowns can be attained When: equipment works better, people work better people work better, factory works better factory works better, people are happier

5 7 STEP Implementation Steps 7. Autonomous Management 6. Standardization Levels Stage-3 Standardize maintenance activities & implement Autonomous Control 5. Autonomous inspection Stage-2 4. General Inspection Assessment of the wear on equipment & Develop activities to prevent it 2. Counter measures against sources of dirt & difficult points 1. Initial Cleaning 3. Develop tentative standards of cleaning, inspection & lubrication Stage-1 Establish Basic Conditions of the Equipment & Maintain those conditions 0. Preparation Get people motivated

6 Example of Implementation

7 Issues that Impact OEE Low operative efficiency GHEE, THE MARKERS ARE NOT GETTING BETTER High # of damages Deficient communicacition LACK OF INTEREST High Nº of accidents Lack of interest of the operators LOSSES DUE TO SETUP LACK OF SKILL DIFFICULTY TO MAKE OUT LOSSES DUE TO DEFECT Lack of skills LOSSES DUE TO RAW MATERIAL

8 Issues of Prod & Maint. OPERATOR Selfish attitude + I OPERATE, YOU REPAIR MAINTENANCE STAFF Negative attitude BE GREATFULL THAT I FIXED YOUR MACHINE = NON PRODUCTIVE MAINTENANCE

9 TPM View Baby Parents Physicians Machines Operators Maintenance

10 Operators Should Be Able To Understand how the equipment works & identify the causes of abnormality Identify & correct equipment abnormalities Understand the relationship between equipment condition & quality of the product; i.e. foresee quality issues & recognize the cause. Carry our repairs Take charge of making improvements; on their own & through working with other departments

11 Autonomous Maintenance Step 0 Step 0 - Initial Preparation Problems and equipment abnormalities cannot be clearly seen when the workplace is unorganized. Cleaning and organizing the workplace helps the team to uncover problems. Making problems visible is the first step of improvement. 5s is a foundation program before the implementation of TPM To make the workplace organised and neat, 1S and 2S needs to be implemented

12 Step 0 1S Sorting the Work Place 1S (Seiri/Sorting) - 1.) Classify necessary & unnecessary tools and equipment around Work Station - 2.) Clear out unnecessary items, take them to salvage area or store - 3.) Sort: - Hand Tools - Gauges - Equipment Accessories - Spares - Cupboards and work tables

13 Step 0 1S Sorting the Work Place 1S (Seiri/Sorting)

14 Step 0 1S Sorting the Work Place Decision Matrix

15 Step 0 2S Organising the Work Place 2S (Organising) - 1.) Decide the right place for each necessary item (location) - 2.) Mark the locations by drawing a boundary around the equipment to indicate its zone - 3.) Exhibit: - Equipment Running - Job Change - Tool Change - Break Down

16 Step 0 2S Organising the Work Place 2S (Organising)

17 Summary Autonomous Maintenance Operator takes ownership of his/her equipment at all times Establish basic conditions of equipment 1S Sorting Classify needed and unneeded items in work area Clear out unneeded items in work area 2S Organising Create a place for every needed item in workplace Pre-fixed locations of tools and equipment Standardise the item location and sustain it