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Slide 1:

AUTONOMOUS MAINTENANCE

Goals Of Autonomous Maintenance:

Goals Of Autonomous Maintenance Prevent Equipment Deterioration Restoration And Proper Management Establish Basic Conditions Train The Operators To Close The Gap Between Them And The Maintenance Staff, Making It Easier For Both To Work As One Team Change The Equipment So The Operator Can Identify Any Abnormal Conditions And Measure Deterioration Before It Affects The Process Or Leads To A Failure

Maintenance Techniques:

Maintenance Techniques Normal Operation Preventive Maintenance Predictive Maintenance Breakdown Maintenance

Activities Of The Production Department:

Activities Of The Production Department Preventing Deterioration: Correct Operation Correct Adjustment Basic Housekeeping Prompt Detection Of Abnormalities Keeping Maintenance

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Measuring Deterioration: Daily Inspection Periodic Inspection Predicting Deterioration: Minor Servicing Prompt And Accurate Reporting Of Failures Assistance With Repairing Failures

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7 Example of A.M. Activity Board People Treasures Definition Team Mission Layout of Line & Identified Important Areas Safety Hazard Contamination Hard-to-reach Main Failure Team Name Members Line Mission Objectives Activity & Findings Step 1: Initial Cleaning Pictures Before After Tag List Production Maintenance Tag Movement Actual Tags Display actual findings from Initial Cleaning such as trash, unnecessary items, dust and other contamination. Step 2: Sources of Contamination Explain and show Focused Improvement activities for sources of contamination One-Point-Lessons Team

Support For Autonomous Maintenance:

Support For Autonomous Maintenance Provide Instruction In Inspection Skills Provide Training In Lubrication Techniques Deal Quickly With Deterioration Contribute Technical Assistance In Improvement Organize Routine Activities Research And Develop New Maintenance Technologies Prepare Maintenance Standards Develop And Use Failure-analysis Techniques Control Technical Data

Basic Equipment Conditions:

Basic Equipment Conditions Optimal Conditions Cleaning Harmful Effects Of Cleaning: Failure Quality Defects Speed Losses Accelerated Deterioration Inspection Checkpoints: Inlets Gauges Storage Lubricating Devices

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1 2 3 4 5 6 7 Autonomous Maintenance 7 steps Countermeasures for Contamination Prepare Temporary Standards General Inspection Autonomous Inspection Standardization Aut. Mgt. 7 6 5 4 3 2 1 Initial Clean-up fuel T P M

Implementing Autonomous Maintenance:

Implementing Autonomous Maintenance Step 1: Perform Initial Cleaning Eliminate Dirt, Dust And Grime Expose All Abnormalities Correct Minor Flaws And Establish Basic Equipment Conditions Expose Danger Points And Practice Accident Prevention Training Step 2: Eliminate Sources Of Contamination And Inaccessible Places Pinpoint And Eliminate Sources Of Leaks And Spills Improve Accessibility To Reduce Working Time

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Step 3: Establish Cleaning And Inspection Standards Top-down Standards Self-set Standards Give Guidance In Preparing Standards Introduce Extensive Visual Controls Step 4 : Perform General Equipment Inspection Developing Equipment-competent Operators Preparing For General Inspection Training Implementing General Inspection Training

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Step 5: Perform General Process Inspection Developing Process-competent Operators Developing The Process INSPECTION TRAINING PROGRAM Step 5.1: Correct Operation Step 5.2: Correct Adjustment Step 5.3: Correct Handling Preparing For General Process Inspection

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Step 6: Systematize Autonomous Maintenance Quality Maintenance And The Systemization Of Autonomous Maintenance Step 7 : Practice Full Self Management Preparing An Autonomous Maintenance Plan Evaluating Equipment Measure The Maintenance Load Clarification Of Maintenance Responsibilities

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15 Initial Cleaning (Initial Inspection & “Restoration ”) 2 . Source of Contamination & Hard-to-Reach areas 3 . Standards of Cleaning 4 . General Inspection 5 . Autonomous Inspection 6. Standardize Autonomous Maintenance operations Autonomous Management -Detect problems of lines and restore its original state. -Start managing the line autonomously. ( 5S, Minor Stops, Quality ) -Create & perform temporary “Cleaning/Lubrication procedures.” -Solve “Sources of Contamination” and “Hard to Reach” areas. (Cleaning, Inspection, Lubrication) -Develop tentative standards for cleaning, lubrication and inspection. -Provide training on their equipments, products and materials, inspection skills and other AM skills. Develop a routine maintenance standard by operators Standardize routine operations related to workplace management such as quality inspection of products, life cycle of jigs, tools, set up operation and safety. Autonomous team working 3 Years

Difficulties Due To High Autonomous Maintenance Loads:

Difficulties Due To High Autonomous Maintenance Loads Model Deployment Step 1: (6 Months) Step 2-3: (9 Months) Area Deployment Area 1: Steps1-4 Area 2: Steps 1-4 Area 3: Steps 1-4 Block Deployment Block 1: Steps 1-3 Block 2: Steps 1-3 Block 3: Steps 1-3 Block 4: Steps 1-3

Autonomous Maintenance Audits:

Autonomous Maintenance Audits It Has Two Advantages: Produce Concrete Results Results Are Confirmed Types Of Audits: Self Audit Section Manager’s Audit Top-management Audit

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HOW AUDITS FUNCTION FOR AUTONOMOUS MAINTENANCE ????

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For Feedback: Mehak Rashid Khan mrk2025@yahoo.com

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