TPM Overview and Autonomous Maintenance

Workshop

1. Understand the concept and philosophy of TPM 2. Learn the 8 Pillars of TPM 3. Understand the key concepts of Autonomous

Maintenance activities 4. Learn the step by step implementation plan of

AM activities 5. Learn the usage of activity boards, meetings

and one point lessons to promote TPM goals 6. Understand the critical success factors in

sustaining Autonomous Maintenance activities on the shop floor

Course Objectives

Total Productive Maintenance (TPM) is a method to achieve maximum equipment effectiveness

through employee involvement

Management + Operators + Maintenance

What is TPM?

Why Is TPM Important? TPM Will improve

teamwork skills and flexibility between operators and maintenance technicians

TPM will improve equipment availability (uptime)

TPM saves money

Equipment is filthy and stays that way

Oil and lubricant leaks are common; lubricators are empty

Rotating parts and moving surfaces are encrusted with chips and raw materials

Common Features of Workplaces with Poor TPM Practices

Machine failures have many hidden causes

Eight Pillars of TPMTPM GOALS: 0 Defect / 0 Breakdown /

0 Accident

5S & Visual Management

Auto

nom

ous M

aint

enan

ce

Focu

sed

Impr

ovem

ent

Early

Equ

ipm

ent

Man

agem

ent

Qual

ity

Mai

nten

ance

Educ

atio

n &

Trai

ning

TPM

in th

e Offi

ce

Safe

ty &

En

viro

nmen

tal

Man

agem

ent

Plan

ned

Mai

nten

ance

Focused Improvement

Autonomous Maintenance

Planned Maintenance

Education & Training

The Four Key TPM Pillars that are Critical for Equipment Reliability

Autonomous Maintenance is maintenance performed by operators

Basic maintenance that can easily be 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

What Is Autonomous Maintenance?

An activity to keep operators busy when product demand is low

Doing a favor for maintenance department

Performing basic maintenance without a purpose

Making operators into skilled technicians

What AM Is Not?

Operator Maintenance

AM is a Paradigm Shift!

We maintain

TPM Attitude

Operator Maintenance

I use I maintain and fix

OLD Attitude

AM- Who Does What

Predictive Maintenance

Breakdown Maintenance

Maintenance Activities

Preventive Maintenance

Robustness Improvement

Start Up & Yield Loss

Defects & Rework

Condition Based Servicing

Trends Measurement & Control

Effective & Appropriate Repairs

Routine Maintenance

Cleaning-Refurbishing

Daily Equipment Care

Lubrication- TighteningDaily Inspection

X

X

X

X

X

XX

X

X

X

X

Prodn Maint

We Need a Culture Change!

Work Systems & Processes

Behavior

Attitude

Culture

By improving equipment & processes….

Changes the way we act……

And the way we think…..

Organization-led activitiesSupported by company and TPM 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 Meetings and reports

Characteristics of AM Programs

KEY CONCEPTS

• Shop floor based activities

• Operator conducted• Operator enhancing• Team Activity• Autonomous

management• TPM Foundation• Part of the job!

3 Key Tools for AM3 KEY TOOLS

• Activity Boards

• Meetings

• One Point Lessons

1. Ability to detect abnormalities2. Ability to correct abnormalities and

restore function3. Ability to set optimum equipment

conditions4. Ability to maintain optimum equipment

conditions

Four Equipment Related Skills for Operators

1. Clean and inspect2. Eliminate problem sources and inaccessible

area3. Draw up cleaning and lubricating standards4. Conduct general inspections5. Conduct autonomous inspections6. Standardize through visual workplace

management7. Implement autonomous equipment

management

7 Steps of Autonomous Maintenance

Initial cleaning of the machine

Identification ofAbnormalityHard to access areasSources of contaminationUnsafe conditions

1. Cleaning and Inspection

Cleaning is inspection Inspection is finding problems Problems demand restoration to original proper conditions and improvement to prevent recurrence

Initial Cleaning is the Foundation of Autonomous Maintenance

Dust Dirt

Leak Rust

Loose

Identification of Abnormalities

Damaged Deformed

Noise Non Standard

Vibration

Identification of Abnormalities

Worn Out Missing

Misalignment Shaking

Identification of Abnormalities

Bolts and Nuts/ JointsLubricationTransmissionHydraulicsPneumatics – gas systemElectricalSafety

Where To Find Them?

Missing Loose Shaking Non Standard Bolts / Washers Corroded Damaged Excess / low length Paint on threads and head

Abnormalities in Bolts & Nuts

Sample Bolts/Nuts Abnormalities

Sample Bolts/Nuts Abnormalities

Sample Bolts/Nuts Abnormalities

Sample Bolts/Nuts Abnormalities

Slackness Tight Damaged Misalignment Noise Pulley/ belt/ gear/ shaft damaged Belt missing Tracking Eccentricity Play

Abnormalities in Transmission

Abnormalities in Transmission

Oil level low / high Oil contaminated Oil pressure low / high Oil temperature high Jerks / Vibration Line damage Line not routed properly Noisy pump Pressure gauge not working Oil leak

Abnormalities in Hydraulic System

Abnormalities in Hydraulic System

Air / gas leak Line damage Line not routed properly Sluggish cylinder movements Filter not drained of moisture Lubricator level low / high Oil flow rate high

Abnormalities in Pneumatic System

Abnormalities in Pneumatic System

Loose connections Hanging wires Cable not routed properly Cable gland loose Motor generating noise Motor generating more heat Exposed wires Panel inlet filter block Panel / junction box open Screws missing Dust / dirt Connections with open wires

Abnormalities in Electrical System

Abnormalities in Electrical System

Abnormalities in Electrical System

1. Don’t be afraid to get your hands dirty during cleaning

2. Remove years of build up grime3. Open covers and lids on areas you have

never checked before. Clean the dirt off every hidden recess of the equipment

4. Don’t just clean the main body of the machine. Remove the grime from auxiliary equipment such as conveyors, gauges, electrical cabinets, and the insides of oil tanks

Tips for Cleaning

1. Look for loose fastenings, slight vibrations, abnormal temperatures and other problems that can only be detected by touch

2. Watch for worn out pulleys and belts, clogged suction filters, grime on sliding surfaces, and other problems that may lead to functional failures

3. Are cleaning, lubricating, and checking easy to do? Do any large covers get in the way? Are oil inlets located conventionally?

Tips for Inspection

Unsafe Places

How to develop Stage 2? Priority of countermeasures Types and sources of contamination Countermeasures for difficult to clean areas Where-where and why-why analysis Use corrugated paper and acrylic cover to

prevent dispersion Use hinge doors instead of fastening screws for

ease of opening Keep records of equipment modifications Review unresolved issues

2. Eliminate problem sources and inaccessible areas

Inaccessible Areas

Elimination of Problem Source

What is lubrication control? Preparation by the Maintenance Department Identify lubricating points and surfaces Allocate routine lubrication tasks Draw lubrication system flowcharts Set tentative lubrication standards Remedy defective area and difficult lubricating

areas Set cleaning and lubrication standards Thoroughly implement a color lubrication control

system

3. Establishment of a LubricationControl System

Lubrication Controls

Lubrication system not working No grease in reservoir No visibility No oil in gear box Lubrication level low/ high Grease / oil leak Without grease nipple and cap Reservoir tank open Excess greasing Oil / grease dust contamination

Abnormalities in Lubrication

Abnormalities in Lubrication

Abnormalities in Lubrication

4. Conduct General Inspection

Conduct General Inspection

5. Conduct Autonomous Inspection

Template 1 – List of Abnormalities

Template 2 - Checklists

Template 3: Audit Plan

Template 4: Status of Abnormalities

Template 5 – Break down register

The concept of making a workplace more effective by making the current condition of a workplace obvious at a glance

Visual management enhances the smooth flow of information by using visual and audio signals instead of texts or other written instructions

It includes a set of techniques that makes operation standards visible so that people can follow them more easily

6. Visual Management

Putting up displays and charts to impress corporate visitors or customers

Cluttering empty walls with visuals as if decorating for a birthday or Christmas party

A one time effort, only to have the visuals or information become outdated over time

Isolated from management standard work

What Visual Management Is Not

Why Visual Management

Applications of Visual Management

Visual Displays (Office)

Examples of Visual Controls

A Good Standard Should Be Visual

Visual Management

Visual Management

Visual Management

Process never ends◦ Metrics◦ Audits

Each process post Results (actual) against Goal (target)◦ Zero lost time accidents◦ Zero Defects◦ Zero Breakdowns◦ Zero set up time or at least < 10 minutes

7. Autonomous Management

1. Proper education and training Are the operators certified? Who certifies them?

2. Development of four equipment related skills3. Establishment of AM schedule for each

operator4. Autonomous management using activity

board and meeting5. Identifying and reporting problems6. Participation in problem solving and OEE

involvement

Key Implementation Points of 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

How to sustain AM?

Critical Success Factors Engaging

employees Aim for early

success Providing active

leadership Share success

stories Rewards and

recognition Continuously

improve OEE

THANK YOU!