INTRODUCTION TO AUTONOMOUS MAINTENANCE – 7 STEPS TO IMPLEMENT SUCCESSFULLY

Autonomous Maintenance (Jishu Hozen) refers to TPM activities that involve operators in maintaining their own equipment, independent of the maintenance department. Activities in an AM program include: daily inspections, lubrication, parts replacement, simple repairs, abnormality detection and precision checks.

The goals of the AM program are to prevent equipment deterioration, restore equipment to its ideal state, and establish basic conditions needed to keep equipment well maintained. AM is one of the most important building blocks in any TPM program.

Companies that have implemented an effective AM program as part of TPM have reported benefits such as significantly reduced downtime, lower cost of maintenance and a higher skilled operative and maintenance workforce.

KEY OBJECTIVES

• Understand the key concepts of TPM and Autonomous Maintenance
• Understand the six big losses that lower equipment efficiency
• Acquire knowledge on how to implement AM activities, step by step
• Learn how to use activity boards, team meetings and one-point lessons to promote TPM goals
• Understand the critical success factors in sustaining AM activities on the shopfloor​

COURSE CONTENT
Module 1
Introduction to Maintenance

• Role of maintenance in operations
• Evolution of maintenance
• Type of maintenance
• Implication of poor maintenance
• Introduction to TPM
• Define TPM.
• Objectives of TPM.
• Primary Benefit
• Secondary Benefits

Module 2
The 8 Pillars of Total Productive Maintenance.

• Focussed Improvement (Kobetshu Kaizen)
• Autonomous Maintenance (Jishu Hozen)
• Planned Maintenance.
• Initial Phase Management (Maintenance Prevention)
• Quality Maintenance
• Training and Education Development
• Office TPM Administrative and Indirect departments
• Safety and Health Environment Management

Module 3
Losses in production process Overall Equipment Effectiveness (OEE)

• Concept of Overall Equipment Efficiency (OEE).
• What is OEE?
• Implication of OEE.
• Measuring OEE?
• The Simple OEE Formulas
  • Availability
  • Performance
  • Quality
  • Overall Equipment Effectiveness
• A Real Example of Calculating Simple OEE
• Interpreting your OEE rating
• Benchmarking of OEE
• Defining World Class OEE?
• Addressing the 6 Major equipment Losses.
  • Machine Breakdowns
  • Machine Adjustments/Setups
  • Machine Stops
  • Machine Reduced Speeds
  • Machine Start Up Bad Parts
  • Machine Production Bad Parts
  • Understanding Chronic losses and Sporadic losses

Module 4
Introduction Autonomous Maintenance (AM)

• Definition of AM.
• What is the Difference Between 5S and AM?
• AM Approach
• AM – Is and Is Not
• AM is a Paradigm Shift
• AM Supports a Culture Change
• Four Equipment-related Skills for Operators
• Concepts of implementing AM.
• Relationship of AM to TPM.
  • Describe the activities in TPM-AM
  • Develop task transfer list for the operators.
• Key Tools for AM Team Activities
  • Activity Boards
  • Meetings
  • One-Point Lessons
• Benefits of autonomous maintenance
• Goals of AM

Module 5

Step by step implementation of AM

• Step 0: Getting Ready.
• Step 1: Initial clean up and inspection of machines.
• Step 2: Eliminating Contamination and Inaccessible Areas
  • Taking counter measures for sources of problems.
• Step 3: Develop Standards for Cleaning, Lubrication and Inspection.
• Step 4: Conduct Inspection and Monitoring.
• Step 5: Autonomous inspection.
• Step 6: Standardize Through Visual Workplace Management.
• Step 7: Fully implement AM program.
• Key Implementation Points for AM
• Role of Management

Module 6
Develop TPM Culture and Improvements.

•  TPM requires culture change
• Measuring & Auditing Autonomous Maintenance Performance
• Performance Metrics for AM
• Three Important Reasons for Audits
• Plan continuous improvement activities.
• Periodic review of AM teams’ performance.
• Overall benefits of AM in the organisation.

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