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5 S

Total productive Maintenance

Autonomous Maintenance

- Step 0

Introduction – Total Productive

Maintenance

Definition: “A structured approach that establishes a corporate culture, that will maximise production system effectiveness”

Aim of TPM:

• Prevent losses and achieve:

• Zero Accidents

• Zero defects

• Zero Breakdowns

in the entire production system life

TPM:

• Total – Involvement of all functions and

people at all levels of organisation

• Productive – Efficient and effective

utilisation of all resources

• Maintenance – Keeping the man-

machine-material system in optimal

condition

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”

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

7 STEP Implementation

1. Initial Cleaning

2. Counter measures against sources of dirt & difficult

points

3. Develop tentative standards of cleaning,

inspection & lubrication

4. General Inspection

5. Autonomous inspection

6. Standardization

7. Autonomous

Management Stage-3

Standardize maintenance

activities & implement

Autonomous Control

Stage-2

Assessment of the wear on

equipment & Develop activities

to prevent it

Stage-1

Establish Basic Conditions

of the Equipment & Maintain

those conditions

Steps Levels

0. Preparation Get people motivated

Example of Implementation

Issues that Impact OEE

Low operative

efficiency

High # of damages

Deficient

communicacition

High Nº of accidents

Lack of interest of

the operators

Lack of skills

LOSSES DUE TO SETUP

LOSSES DUE TO DEFECT

LOSSES DUE TO RAW MATERIAL

GHEE, THE MARKERS ARE NOT

GETTING BETTER

LACK OF

INTEREST

DIFFICULTY TO MAKE OUT

LACK OF

SKILL

“I OPERATE, YOU REPAIR”

OPERATOR

MAINTENANCE

STAFF

“BE GREATFULL THAT I FIXED YOUR MACHINE”

Selfish attitude

Negative attitude

=

+

NON PRODUCTIVE MAINTENANCE

Issues of Prod & Maint.

TPM View

Operators

Baby Parents Physicians

Machines Maintenance

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

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

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

Step 0 – 1S Sorting the Work Place

1S (Seiri/Sorting)

Step 0 – 1S Sorting the Work Place

Decision Matrix

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

Step 0 – 2S Organising the Work Place

2S (Organising)

Summary

1S Sorting

• Classify needed and unneeded items in

work area

• Clear out unneeded items in work area

Autonomous Maintenance

• Operator takes ownership of his/her equipment at all times

• Establish basic conditions of equipment

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