Professional Documents
Culture Documents
and
Autonomous Maintenance
ANAND U 1
A Brief History-TPM
Total Productive
Maintenance
1971 - Present
Productivity Maximisation by :
P - PRODUCTIVE
•Zero Accident
•Zero Defect
•Zero Breakdown
Autonomous
Maintenance
Planned
Maintenance
Education &
Training
Pillars of TPM
ANAND U
Early Equipment
Management
8 Pillars of TPM
(1989 – Present)
Quality
Maintenance
Indirect
Department
Defects
Minor Stoppages
ANAND U
C/Over & Adj
Reduced
Speed
Start-up
Loss
7
Natural Forced
Deterioration Deterioration
Breakdowns !
Maintenance Person :
Possess ability to do Maintenan
on all types of Equipment
ANAND U 11
Objective:
To restructure the
corporate culture
through behavioral
changes and equipment
improvements.
TE
AR LL
DOW WA
N
THE
ANAND U 12
Intent:
ANAND U 13
Purpose:
To identify productivity
losses and involve all
members of the company
in loss elimination
programs.
L O S S
ANAND U 14
What Are The Benefits ?
ANAND U 15
What Can Be Expected?
Productivity:
Valueadded improvement 1.5 to 2 times.
40% reduction in breakdowns.
Overall equipment efficiency up 1.5 to 2 times
Quality:
Reduction in Work-In-Process (WIP) defects.
Reduction in Parts Per Million (PPM).
Cost:
Production costs reduced by 30%.
Quality cost reduced by 30%.
ANAND U 16
What Can Be Expected?
Delivery:
Reduced finished goods inventory by 50%.
100% on-time delivery.
Reduced premium freight by 60%.
Education:
Skill upgrading of employees.
ANAND U 17
Equipment Failure Statistic
Autonomous Maint.
Lubrication Method Role in B/D
Reduction
13%
Lack Of Cleaning
Dirt Lubricant
12% 24% Lubrication
Inspection
Loose Parts
8% Tightening
Other Equip.
Failures
43% Source: JIPM
ANAND U 18
Overview of Eight Pillars
ANAND U 19
Pillar : Planned maintenance
ANAND U 20
Pillar : Focused Improvement
Aim :
•To focus on specific losses & Increase productivity, ease of
operation & Standardization of methods
•To ensure adequate methods for identification of losses &
countermeasure implementation
•To increase ease of detecting / correcting deterioration of
equipment
ANAND U 22
Pillar : Initial flow control
Aim : Shorten the trial period for new product, design of new
equipment, and run-up time for stable launching of
products
Method:
•Set forth development and design targets
•Easy to manufacture, maintain and reliable equipment
•Study of LCC
•Review of design methodologies
ANAND U 23
Pillar : Quality Maintenance
ANAND U 24
Pillar : Safety
ANAND U 25
Pillar : Office TPM
ANAND U 26
TPM General Master Plan
Kick off TPM Award
DATA MGT.
TPM DATA MONITORING ON EACH LINE
Individual
Improve ANALYSIS OF B/DOWN & MINOR STOPS
BREAKDOWN ANALYSIS
Planned IMPROVE WEAK POINT PARTS
Mainten ESTABLISH PM STANDARDS
ance
PREDICTIVE MAINTENANCE
ANAND U 27
Understanding
Losses
ANAND U 28
16 Major Losses
Which Obstruct Production Efficiency
ANAND U 29
16 Major Losses - Continued
1. Management Loss
2. Operating Motion Loss
3. Line Organization Loss
4. Logistics Loss
5. Measurement &
Adjustment Loss
ANAND U 30
16 Major Losses - Continued
1. Energy Loss
2. Die, Tool, & Fixture Loss
3. Material Loss
ANAND U 31
16 Major Losses - Continued
8 Major Losses Obstructing Equipment Efficiency:
ANAND U 32
16 Major Losses - Continued
8 Major Losses Obstructing Equipment Efficiency:
3. Consumable Parts Change Loss: Weld tip, weld liners,
cutting bits
ANAND U 33
16 Major Losses - Continued
ANAND U 34
Autonomous
Maintenance
ANAND U 35
Autonomous Maintenance
Purpose:
Prevent equipment from forced deterioration
Keeping one's own equipment in good condition by
oneself
Members:
Operator, Cell Coordinator
Activities:
Initial cleanup
Countermeasure for HTA & SOC
Creation of autonomous standards for equipment
Daily CLIT activity
Training of operators proficient in equipment
Adequate compliances with basic and usage
requirements of equipment
ANAND U 36
Autonomous Maintenance
ANAND U 37
The Goal Of
Autonomous Maintenance
ANAND U 38
Types of Deterioration
Natural Forced
Deterioration Deterioration
Breakdowns !
ANAND U 41
TPM Roles Of
Operators Maintenance
Management
ANAND U 42
Seven Steps of
Autonomous Maintenance
Autonomous Maintenance
Standardization
Autonomous Inspection
General Inspection
Initial Cleanup
ANAND U 43
AM Step Zero
Preparation for Step 1
Safety education about equipment
Basic knowledge about machine
structure
Arrangement of cleaning material
ANAND U 44
ANAND U 45
ANAND U 46
Machine / Lock Photo
ANAND U 47
AM Step One
Initial
Cleaning
ANAND U 48
Initial Cleaning Cleaning is
Inspection
ANAND U 49
Cleaning is
Initial Cleaning – Continued...... Inspection
ANAND U 50
TPM Tags
TPM
Autonomous Maintenance TPM
Autonomous Maintenance
Step. No. 12 3 4 5 Step. No. 12 3 4 5
Problem Found Here Problem Found Here
Equipment: Equipment:
A
: sset No.: A
: sset No.:
Date Found: Date Found:
Found By: Found By:
Description of Problem: Description of Problem:
ANAND U 51
Tag History
Upon completion of the repair, log or file
tags for future reference.
Keep the information at the cell.
Red tag history highlights:
Recurring problems
Repair history
Maintenance response
White tag history highlights:
Operator repairs and minor stoppages
Recurring problems that need to be red tagged
ANAND U 52
Things to Look for During Cleaning
Looseness
Breakage, Deformation, Crack
Wear & Tear
Play, Slack
Misalignment
Poor soldering
Poor wiring
Rust
Contamination
Oil leaks
Unwanted parts
ANAND U 53
AM Step Two
ANAND U 54
Countermeasures For
Hard-to-Access Areas
ANAND U 55
Countermeasures For
Source of Contamination
ANAND U 56
Steps In Preparing A Temporary Guard
Observe Line
Suggest As
Standardization And
Future Design Information
ANAND U 57
Hard-To-Access & Source Of Contamination Areas
Equipment Asset Page
No.:____________________
Name:____________________ No.:____________________
ANAND U 58
AM Step Two: Benefits
Contamination is stopped at source.
Contamination is controlled/
minimized .
Access is improved to areas that are
difficult to Clean, Lubricate, Inspect
and Tighten.
Time taken for CLIT activities is
reduced.
ANAND U 59
AM Step Three
Preparation
Of
Temporary
Standard
This step is to enhance the equipment
reliability & maintainability
ANAND U 60
Temporary Check Sheet for CLIT
ANAND U 61
Temporary Standard - C L I T Sheet
Autonomous Maintenance – Step 3
SN What Item What to do How When Who Target
Time
ANAND U 62
Visual Control to Support AM Step 3
ANAND U 63
Visual Control to Support AM Step 3
ANAND U 64
Equipment Failure Statistic
Autonomous Maint.
Lubrication Method Role in B/D
Reduction
13%
Lack Of Cleaning
Dirt Lubricant
12% 24% Lubrication
Inspection
Loose Parts
8% Tightening
Other Equip.
Failures
43% Source: JIPM
ANAND U 65
One Point Lesson
Tool to convey information regarding
knowledge and skill of equipment, and
about trouble/improvement cases.
Designed to help enhance knowledge and
skill in a short period of time at just the
right time whenever required.
To upgrade the level of expertise of whole
circle.
To encourage every member to think,
study and prepare OPL and teach to all
the team members.
ANAND U 66
One Point Lesson
Correct usage of part of equipment
Generating sources
Difficult to access location
Structure and function of machine
Inspection method
ANAND U 67
Key Points For Success In Implementation
ANAND U 68
Key Points For Success In Implementation
Transmission Of Education
One Point Lesson Sheet
Standardization
Activities Board:
Timing Chart One Point Lessons
# Of Equipment Failures Defect Rate
# Of Minor Stoppages Current Step In Progress
Changeover Time Problem Tag Data
"Before" & "After" Pictures Downtime Data
Clean-up Time Equipment Check Time
Maintenance Costs Accidents
ANAND U 69
Key Points For Success In Implementation
Quick Repair
TPM Meetings
Step System
Step Audit
Promote Success Stories
ANAND U 70
Autonomous Maintenance Audit
ANAND U 71
AM Step Four
General
Inspection
ANAND U 72
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ANAND U 73
AM Step 4 – General Inspection
This is three days training module
conducted by Anand U Pune Team.
This consist of basic knowledge of
Electrical, Electronics, Hydraulics,
Pneumatics, Bearing & Lubrication,
Fasteners and Power Transmission
Devices.
How to do day-to-day maintenance of
machine elements.
Dos and Don’ts of machine operation.
ANAND U 74
General Inspection
ANAND U 75
Skill Assessment
1 Ashok
2 Mohan
ANAND U 76
Machine Mechanism
Training
Hydraulics
Pressure gauge
4
3 5
2 6
Lubrication Pneumatics 1 bar 7
Operators
Skill
&
Knowledge
3
Water Oil
Fasteners Electrical
ANAND U 77
Use of Five Senses:
•Abnormal Sound
•Vibration
•Excess Heat
•Abnormal Smell
Hydraulics:
Lubrication: •Hydraulic oil level
•What to lubricate
•Room temp.
•When to lubricate
•Types of lubricants
•Pressure
for each point •Relief valve
•How to lubricates •Pump
•Cleanliness of •Filter
lubricants Regular •Leakage
Inspection
of
Machine
Pneumatics:
Elect & Electro •Air pressure
•Current •Air filter
•Voltage •Regulator
•Loose connections •Lubricator
•Equipment safety •Drain point
•Self safety •Air leakage
ANAND U 78
Training Program
by
Subject Maintenance
Faculty Team
Operator
ANAND U 79
Operators’ Training
Machine
Process
Mechanism
Training
Training
ANAND U 80
Hydraulics
Proximity
Pneumatics
Sensors
Topics
Electrical
Identified Bearing &
For Lubrication
Training
Drives Safety
Fasteners
ANAND U 81
e r s
te n
Fas
ANAND U 82
ANAND U 83
AM Step Five
Autonomous Inspection
ANAND U 84
Autonomous Inspection
Draft autonomous inspection check sheet
(Formal/Final Jishu Hozen Standard) for
Cleaning, Lubrication, Inspection and
Tightening of equipments.
This final standard will be based on
tentative standard drafted during AM
step 3.
Consider the results of AM step 4, in
drafting final Jishu Hozen standard.
Clarify and define the role of production
and maintenance department in
preventive maintenance of equipments.
ANAND U 85
PM Implementation
Role Role
.
of of .
Prod. Maint.
ANAND U 87
Preventive Role of Maintenance
Maintenance Department
• Scheduled preventive
• Spare parts management
maintenance
• Monitoring maint
• Breakdown analysis
measures as MTBF, MTTR
Aim Should be
Productivity Improvement
ANAND U 89
1.
1.
Cleaning
Cleaning
7.
7.
Early
Early 2.
2.
Detection
Detection Lubrication
Lubrication
of
ofm/c
m/c
Abnormality
Abnormality
Job
Jobofof
Operator
Operator
6.
6.
in
in
Prev 3.
3.
Minor
Minor PrevMaint
Maint Inspection
Repairs Inspection
Repairs
5.
5. 4.
4.
Proper
Proper Tightening
Tightening
Operation
Operation
ANAND U 90