The relationship between Operators and Maintenance

Operator Equipment Maintenance

Parents Child Family doctor

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Autonomous Maintenance
Step 1 to Step 3
 Review: What is AM?

Operators need the ability to:

1) Recognise abnormalities when they see them

(The ability to identify abnormalities)

2) Respond swiftly and correctly when abnormalities occur

(The ability to take corrective action)

3) Set clear criteria defining what is normal and what is not

(The ability to set conditions)

4) Keep strictly to the rules governing these conditions

(The ability to sustain)
 Review: What is AM?

More specifically, each operator needs to acquire the ability to:

1) Identify and correct equipment abnormalities

2) Understand how the equipment works,

and identify the causes of any abnormality

3) Understand the relationship between the equipment

and the quality of the product, foresee quality problems,
and find out what is causing them

4) Carry out repairs

5) Implement appropriate Focused Improvements,

either independently or in cooperation with other
departments
 Objectives of AM

The basic precepts of Autonomous Maintenance

1) The problems that stop equipment from working, or make it work less effectively,
can be completely eliminated – in other words, zero-defect, zero-breakdown status
can be attained – by changing the way everyone who works with the equipment,
including the operators, thinks and behaves.

2) When the equipment works better, the people work better, and when the people
work better, the whole factory works better.

3) Autonomous Maintenance should be introduced step by step under the guidance

of management, with each step implemented thoroughly. It should involve the
whole workforce and empower each individual to fulfil his or her potential.
 Raising the Level of Equipment, Operators and Activity in a
Continuous Upward Spiral

1 Develop the ability to take appropriate action and recover the situation
14 Develop truly
Aims 7 Develop the ability to equipment-competent
2 Develop the ability to 10 Develop the ability to operators
establish correct
detect abnormalities sustain and control
conditions

11 Does not break down

3 Does not suffer from 8 Is continually improved
Equipment or produce quality 15 Is highly productive
forced deterioration in pursuit of the ideal defects

4 Are able to recognise

equipment problems 9 Know how the 12 Understand the 16 Can fix the
equipment is relationships between
Operators 5 Think and act in the constructed and how it the equipment and equipment when it
kaizen (continual works product quality goes wrong
improvement) way

6 What have we been lacking up to now? 13 What must we do from now on?
- Embed the autonomous maintenance programme - Build a strong culture in which an autonomous
Activity and get it firmly established - maintenance programme with real 100%
participation can flourish -
 The Steps to Autonomous Maintenance and How they Work
STEP 1
STEP 0 STEP 4 STEP 6
STEP 2 People’s thinking
(PREPARATION) STEP 5 STEP 7
STEP 3 changes:
Defects and Benefits:
Benefits: People
Equipment breakdowns start to Zero defects The whole
Get people Fewer start
starts working be seen as something and zero factory works
motivated better defects and working
break-downs to be ashamed of failures better
better
are attained
People’s behaviour
Think, then Fix minor equipment changes:
act defects They take the trouble
to make
improvements
Action •Cleaning is inspection They make
generates •Inspection is detection improvements stick,
motivation •Detection is correction (and and manage their
improvement) work more carefully
Get people to
ask themselves
why forced Hone people’s
deterioration fault-detecting •Correction is perfection •Positive change filters upwards
happens, and capabilities and get •Perfection is satisfaction from the bottom
help them them thinking in •Satisfaction is further action •Operators take control of
understand why terms of identifying and solving problems
Autonomous improvements
Maintenance is
needed
People’s attitudes and behaviour will not
change until they see results
 Classifying and Allocating Maintenance Tasks 1

The activities necessary to achieve the maintenance objective can be broadly

divided into the following two types:

1. ‘Sustainment’ activities: Preventing and correcting equipment failures.

2. ‘Improvement’ activities: Prolonging the working life of the equipment, reducing the time spent
on maintenance, and eliminating the need for maintenance.

These two types of activity need to be carried out in parallel.

Measures for ‘sustaining’

• Correct operation.
• Routine maintenance, periodic maintenance, predictive maintenance.

Measures for ‘improving’

• Corrective maintenance: improving equipment reliability and maintainability.
• Maintenance prevention: designing out the need for maintenance.
 Classifying and Allocating Maintenance Tasks 2
Specific Activity Department Responsible
Type of Task Preventing deterioration Measuring deterioration Reversing deterioration Production Maintenance
Correct Correct Operation
Operation
Setup and Adjustment
Cleaning-exposing and dealing with potential problems
Preventive
Maintenance Lubricating
Routine
Checks Tightening
Routine checking of deterioration and conditions of use
Minor Servicing
Productive Maintenance

Periodic Periodic Checking

Maintenance
Periodic Inspection
Periodic Servicing
Predictive
Maintenance Trend Inspection
Non-Periodic Servicing
Strengthening
Corrective
Maintenance Reducing Loads
(Reliability)
Corrective Improving precision
Maintenance
Corrective Maintenance Developing Condition Monitoring Techniques
(Maintainability) Improving Inspection Work
Other: operability, safety Improving Servicing Work
etc.
Improving Servicing
Maintenance Quality
Prevention Maintenance Prevention

Breakdown Intentional Breakdown Maintenance

Maintenance Quick identification of problems, prompt
Emergency action and accurate reporting
Maintenance Repairing unexpected
failures
 The Seven Autonomous Maintenance Steps

Step Name Activities

Initial cleaning Eliminate dust and dirt from main body of equipment, lubricate and tighten, expose and deal
1
(cleaning is inspection) with equipment problems.
Contamination sources Reduce housekeep in time by eliminating or containing sources of dust, dirt or other
2
and hand-to-access areas contamination, and improving places that are hand to clean, lubricate, tighten or check.
Formulate provisional standards to enable cleaning, lubricating, tightening and checking to be
Provisional Autonomous
3 sustained dependably with minimal time and effort(this will mean establishing time slots for
Maintenance standards
routine and periodic maintenance).

Train operators in inspection procedures using inspection manuals, enabling them to expose
General equipment
4 and correct equipment defects by performing comprehensive equipment inspections.
inspection

Formulate definitive cleaning, lubrication and inspection standards that can be followed
5 Autonomous inspection efficiently and dependably, draw up autonomous inspection checklists and put them into use.

Develop a comprehensive housekeeping system by devising additional standards for items

such the following:
•Movement of materials around the shop floor
6 Standardisation
•Data recording
•Control of moulds, jigs, tools, etc.
•Quality assurance data on the process

Roll out and implement company policies and objectives, and continually improve the
7 Full self-management equipment by keeping accurate MTBF and other maintenance records, analysing the data
captured, and doing improvements as a routine part of the job
 Preparation (Step 0)

1. Understand the objectives

Hold meetings for:
*Make sure operators understand why
Autonomous Maintenance is necessary
•Team members
*Make sure operators understand why basic •Team leaders
equipment conditions need to be sustained •Managers and supervisors
*Have operators observe their own equipment

2. Draw up plans
•Draw up a list of injuries and accidents that could happen during initial cleaning
(such as electric shocks, injury due to residual air pressure, skin irritation by
1) Safety cleaning agents, foreign objects in the eye, injury by falling objects, and so forth)
•Provide safety training and establish procedures for predicting and averting
hazards (unsafe conditions and behaviours)

Loose bolt
Forced deterioration and •Find out what is causing forced deterioration
2) consequent losses •Find out what losses are caused by forced deterioration
•Find out what situations result in quality defects,
breakdowns and minor stops

Ensure that operators •Draw simple diagrams showing how the equipment works
understand their •Make sure everyone understands the mechanisms
3) equipment •Consider what problems might happen if a mechanism Build-up of used
gets dirty or runs out of lubricant, or if any bolts, etc. cutting fluid
work loose

•Cleaning: Techniques for removing dirt efficiently,

Skills needed ways to detect equipment problems
4) •Lubrication: Purpose, types, method, quantity, interval
Tightening: Purpose, correct method, correct use of tools
 Some Harmful Effects of Inadequate Cleaning

When dirt or debris gets into rotating or sliding parts, pneumatic or hydraulic
systems, electrical control systems, sensors, or other components, it can
Breakdowns create problems such as wear, blockage, electrical resistance defects and
electrical conduction defects, which can in turn cause malfunction,
breakdown, loss of precision, etc.

Foreign matter in equipment can be directly transferred to products, or can

Quality defects
cause the equipment to malfunction, leading to quality defects.

The presence of dirt makes it more difficult to spot abnormalities such as

Forced deterioration
loose parts, cracks, rattling, or oil leaks, and they may be overlooked.

Dirt in equipment increases rotational friction and sliding resistance, lowering

Speed losses
production capacity and causing idling and other speed-related problems.
 Workflow for Step 1 (Initial Cleaning)
Step 1: Initial Cleaning (checking- through-cleaning)
Aims
By completely eradicating dust and dirt from the main body of the equipment and its surroundings, to
· Prevent forced deterioration;
· Detect and rectify latent minor equipment defects through the cleaning process.
Why is initial cleaning necessary? Preparation
· Understand the aims of Step 1 (Detailed plan) Cleaning map
Compile a list of requirements · Understand precisely what tasks are involved
Draw up a plan · Draft a detailed work plan Combine

Target for number of Execute cleaning blitz

minor equipment 1 Clean away dust and dirt, inspect equipment, detect and rectify latent defects.
defects to be detected 2 Sustain basic standards for cleaning, lubricating and tightening. Compile a list of Tag
3 Detect sources of contamination and hard-to-access areas, and take provisional defects defects
‘Sort and store’ corrective action. detected
standards 4 Sort and store unneeded items, tools and spares.

Hold meetings to: Compile a list of equipment defects

•Devise improvement methods (1) Decide which restoration and •Micro-defect detection list
•Assign responsibility for improvements improvements can be carried out Problem status and solution
(include general staff as well as operators) during Step 1
-where dust and dirt are found
•Explore the reasons behind the defects •List of hard-to-clean areas
•List of entry points for foreign matter
(2) Restore and improve Some defects have to be left over until the next step
•List of superfluous and inessential items
Guidance

Check results and de-tag

Improvement record
Formulate provisional cleaning standards
Hold a team meeting
Conduct self-review
Activity board Apply for factory review
Receive factory review
·…………….
·……………. Submit activity report

Pass Step 1
·……………. Submit improvement activity
status report
 Workflow for Step 2
(Tackling Contamination Sources and Hard-to-Access Areas)
Step 2: Tackling Contamination Sources and Hard-to-Access Areas
Aims
• Eliminate sources of dust, dirt and other contaminants, prevent scattering, and shorten the time needed for cleaning,
lubricating and inspecting by improving inaccessible areas;
• Help operators to acquire the equipment-improvement mindset, creating real benefits for the business.

Understand the Locate the areas where dust, dirt and foreign matter Hard-to-access areas are areas which:
harmful effects of dust, accumulate • take a long time to clean, lubricate or inspect
Analyse dust, dirt and foreign matter to identify their • are awkward to clean, lubricate or inspect
dirt and foreign matter
material, shape and composition
Collect hard data Which tasks are affected by the difficulty?
Find out exactly where the contamination is coming from: •Cleaning/lubricating/tightening
•Is it coming from the previous process? •Which tools are used?
Why is the •Does the difficulty make it impossible to
contamination •Is it generated by this process? perform the task?
happening? •Is it generated in the course of machining? •In what way is the result checked?
•Is it coming from the equipment? •Is the work performed by eye, using the bare
•Is it coming from the external environment? hands, etc?

Plan countermeasures Plan Display target

•Cut off contamination source countermeasures times for routine
Cultivate improvement- •Prevent scattering •Set time targets cleaning and
oriented mindset •Prevent contaminants getting into or settling on equipment
•Decide improvement inspection
•Set action schedule and assign responsibilities
methods

Restore and improve Record improvements

Check results Revise provisional standards
Revise provisional cleaning standards drafted in Step 1 and
Eliminate
Guidance

subsequently improved
Minimise Perform cleaning based on
provisional cleaning standards Check that cleaning can be Activity board
Localise carried out properly in the time ·…………….
Conduct self-review allowed by the provisional
standards, and remove tags ·…………….
Receive factory review ·…………….
Draw up team activity report and
Pass Step 2 apply for a factory review
 Workflow for Step 3
(Provisional Autonomous Maintenance Standards)
Step 3: Formulating Provisional Autonomous Maintenance Standards
Aims
• To formulate basic conditions for activities designed to prevent equipment deterioration, and to sustain cleaning,
lubricating and tightening;
• To self-formulate action standards enabling these basic conditions to be faithfully upheld with minimal expenditure of time;
• To promote visual control.

Documents from Cleaning and Inspection

Steps 1 and 2: •Areas to be cleaned and inspected To be provided by
Lubrication
List of micro- •Methods to be used maintenance department
• Parts to be lubricated, type and
defects detected •Standards to be achieved quantity of lubricant, lubricating tools Lubrication
manuals
•Action to be taken against irregularities and lubricating intervals
List of
•Cleaning and inspection intervals • Detection of minor equipment defects
improvements
•Time targets in the course of lubrication Lubrication
Checksheet for • Improvements to lubrication methods training
time targets • Time targets

Visual controls used

Formulate standards Determine what was wrong with the existing
Clean, lubricate and inspect standards
Find out why these standards could not be
Measure time gap sustained
Guidance

Improve Improvement record

Activity board
·……………. Check results
Activity record
·……………. Conduct self-review
·…………….
Draw up team activity report and apply for a factory
Receive factory review review

Pass Step 3