TPM: Autonomous Maintenance (Jishu Hozen)

1. Autonomous Maintenance © Operational Excellence Consulting. All rights reserved. 1 © Operational Excellence Consulting. All rights reserved.

2. NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg Learning Objectives Understand the fundamental principles and concepts of TPM and AM activities, including core practices such as cleaning, inspection, and lubrication. Learn the step-by-step process for implementing AM activities, including the use of activity boards, meetings, and one- point lessons to drive TPM objectives. Gain proficiency in measuring, auditing, and evaluating the effectiveness of AM activities, while also becoming familiar with the JIPM TPM excellence criteria for AM. Understand the critical success factors involved in sustaining AM activities on the shop floor. 2 © Operational Excellence Consulting. All rights reserved.

3. Contents Measuring & Auditing AM Activities Key Concepts & Principles of TPM & AM Activities 1 1 5 5 Core Practices of AM: Cleaning, Inspection, Containment & Lubrication JIPM TPM Excellence Criteria for AM 2 2 6 6 3 3 7 7 Key Tools of AM Activities Sustaining AM 4 4 The 7 Steps of AM 3 3 © Operational Excellence Consulting. All rights reserved. © Operational Excellence Consulting. All rights reserved.

4. Machine Failures Have Many Hidden Causes Failure is what we see but is only the tip of the iceberg Visible Failure Contamination Wear Loosening Minor machine defects are generally unnoticed but are the cause of almost all machine failures Less Visible Leaks Corrosion Deformation Flaws Cracks Vibration Improper Temperature Backlash 4 © Operational Excellence Consulting. All rights reserved.

5. TPM Goals § Maximize equipment effectiveness § Zero breakdowns § Zero defects § Zero accidents Zero waste! 5 © Operational Excellence Consulting. All rights reserved.

6. TPM Drives the “Three Evils” Out of the Workplace Danger Difficulty Dirt Difficult tasks are hard to do right because they are so fatiguing. Dirt is more than just unsanitary. If neglected, it can cause equipment to break down and create unsafe conditions. Such conditions create a dangerous workplace and sooner or later will cause major accidents. Use TPM to eliminate difficulty, dirt and danger from the workplace and create a working environment where it is easy to work. Source: Adapted from “TPM for Every Operator” by JIPM 6 © Operational Excellence Consulting. All rights reserved.

7. TPM is a Paradigm Shift Operator Maintenance Operator Maintenance I maintain & I fix I use We maintain Old Attitude TPM Attitude 7 © Operational Excellence Consulting. All rights reserved.

8. AM Supports a Culture Change Culture Attitude And the way we think… Behavior Changes the way we act… Work Systems & Processes By improving equipment effectiveness… 8 © Operational Excellence Consulting. All rights reserved.

9. Autonomous Maintenance Objective: To place responsibility for routine maintenance (e.g. cleaning, lubricating, and inspection) in the hands of operators. § Key Benefits: • Gives operators greater “ownership” of their equipment • Increases operators’ knowledge of their equipment • Ensures equipment is well-cleaned and lubricated • Identifies emergent issues before they become failures • Frees maintenance personnel for higher-level tasks 9 © Operational Excellence Consulting. All rights reserved.

10. AM Activities Improve Equipment Efficiency and Upgrade Operator Skills Equipment- focused Equipment Maintenance Skills Detect Correction & Restoration Abnormalities Maintain Optimum Equipment Conditions Cleaning is Inspection Autonomous Maintenance Traditional Culture TPM/Lean Culture Learn Equipment Structure & Function Autonomous Management Operator’s Knowledge Visual Workplace Standards & Inspection Operator- focused 10 © Operational Excellence Consulting. All rights reserved.

11. Goals of Autonomous Maintenance Equipment Restoration & Proper Management Prevent Equipment Deterioration Establish Basic Conditions Goals of Autonomous Maintenance 11 © Operational Excellence Consulting. All rights reserved.

12. Four Equipment-related Skills for Operators Detect 1 Abnormalities Correct & Restore Abnormalities 2 Set Optimum Equipment Conditions 3 Maintain Optimum Equipment Conditions 4 12 © Operational Excellence Consulting. All rights reserved.

13. Autonomous Maintenance Approach Execute & follow standards & rules Examine & expose problems Do Check Plan Act Prevent recurrence through improvement Counter & solve problems Source: Adapted from Society for Maintenance & Reliability Professionals 13 © Operational Excellence Consulting. All rights reserved.

14. The 7 Steps Of Autonomous Maintenance Implement Autonomous Equipment Management 7 Standardize through Visual Workplace Management 6 5 Conduct Autonomous Inspections Conduct General Inspection Skills Training 4 Develop Cleaning & Lubricating Standards 3 Eliminate Problem Sources & Inaccessible Areas 2 1 Clean and Inspect 14 14 © Operational Excellence Consulting. All rights reserved. © Operational Excellence Consulting. All rights reserved.

15. Initial Cleaning is the Foundation of AM Cleaning is inspection What is Cleaning? Inspection is finding problems Resolve issues and improve to prevent future problems Cleaning serves as inspection; it reveals hidden problems and ensures thorough maintenance. 15 © Operational Excellence Consulting. All rights reserved.

16. Three Key Reasons for Lubrication Problems 1 2 3 Failure to adhere to correct lubrication standards Absence of lubrication standards Use of wrong standards 16 16 © Operational Excellence Consulting. All rights reserved. © Operational Excellence Consulting. All rights reserved.

17. 3 Key Tools for AM Team Activities Activity Boards One-Point Lessons Meetings 17 17 © Operational Excellence Consulting. All rights reserved. © Operational Excellence Consulting. All rights reserved.

18. Example: AM Activity Board People Activity & Findings Results Team Mission Team Display actual findings from Initial Cleaning such as trash, unnecessary items, dust and other contamination Step 1: Initial Cleaning • Mission • Objectives • Team Name • Members Definition Step 2: Sources of Contamination Pictures Before After Line Explain and show Focused Improvement activities for sources of contamination Layout of Line & Identified Important Areas Production Maintenance Tag List One-Point-Lessons Safety Hazard Contamination Tag Movement Hard-to-reach Actual Tags Main Failure 18 © Operational Excellence Consulting. All rights reserved.

19. Types of One-Point Lessons Basic Knowledge Lesson Examples of Problems Examples of Improvement Training tool to fill knowledge gaps, focusing on equipment subsystems, safety points, or basic operating information. Lessons based on past issues, aiming to prevent similar problems in the future. Lessons on successful improvement ideas, describing approaches, actions, and results of specific improvement projects. 19 © Operational Excellence Consulting. All rights reserved.

20. The 7 Steps Of Autonomous Maintenance Implement Autonomous Equipment Management 7 Standardize through Visual Workplace Management 6 5 Conduct Autonomous Inspections Conduct General Inspection Skills Training 4 Develop Cleaning & Lubricating Standards 3 Eliminate Problem Sources & Inaccessible Areas 2 1 Clean and Inspect 20 © Operational Excellence Consulting. All rights reserved.

21. 7 Steps of Autonomous Maintenance Steps of AM Main Objective 1. Clean and inspect 2. Eliminate problem sources and inaccessible areas To keep the state of the equipment from deteriorating 3. Develop cleaning and lubricating standards 4. Conduct general inspection skills training General inspection standards to complement the first 3 steps 5. Conduct autonomous inspections 6. Standardize through visual workplace management Focus on the entire work area 7. Implement autonomous equipment management Independent maintenance activities as part of business as usual 21 © Operational Excellence Consulting. All rights reserved.

22. Step 1 – Clean and Inspect Eliminate all sources of dirt and grime on the machine, lubricate, tighten bolts, and find and correct problems. § Eliminate all dirt and grime on the machine, lubricate and tighten bolts § Find and correct problems § Implement the Activity Board and the 4Ms § Address operators’ questions during education process § Develop countermeasures to mis-operations as early as possible 22 © Operational Excellence Consulting. All rights reserved.

23. Example of Tagging Afterwards – Everyday process During initial cleaning Tag is removed only after the repair is made 23 © Operational Excellence Consulting. All rights reserved.

24. Example: Establish Cleaning Standard Autonomous Maintenance Routine Cleaning, Inspection, & Lubrication Standard Area : Bag Printer Dept. / Line : Mach. ID : Date: Tag # : Bldg Y 4/28/2004 T (Min) Person Resp. Freq Diagram No. Item Criterion Method Tools S D W M Cleaning Water trap 1 Empty bowl Open valve Cloth 1 X Operator This is the maximum level for water in the bowl. Insert Open valve at bottom to release water, wipe up with clean cloth. Picture Here 24 © Operational Excellence Consulting. All rights reserved.

25. Step 4 – Conduct General Inspection Skills Training Conduct skills training with inspection manuals and use general inspections to find and correct slight abnormalities in the equipment. § Train operators in skills like pneumatics, electrical, hydraulics, lubricant and coolant, drives, bolts, nuts and safety § This is necessary to improve the technical skills of operators and to use inspection manuals correctly § After acquiring the new knowledge, operators should share them with others, e.g. through 1-point lessons § By acquiring the new technical knowledge, operators are now well aware of machine parts 25 © Operational Excellence Consulting. All rights reserved.

26. Example: AM – Who Does What? Maintenance Activities Production Maintenance ✔ ✔ Robustness Improvement Breakdown Maintenance Effective And Appropriate Repairs ✔ ✔ Trends Measurement And Control Predictive Maintenance Condition Based Servicing ✔ ✔ Building Of Programs Preventive Maintenance ✔ ✔ ✔ ✔ ✔ Time Based Applications Cleaning - Refurbishing Lubrication & Tightening Routine Maintenance Daily Inspection Daily Equipment Care 26 © Operational Excellence Consulting. All rights reserved.

27. Visual Control Example: Lubrication Mark lubrication points with a label that identifies the proper grease quantity and frequency. To ensure that the correct lubricant is used, consider also color coding the lube point label to match the label on the appropriate grease gun. Source: Adapted from Brady 50 Lean Visuals Pocketbook 27 © Operational Excellence Consulting. All rights reserved.

28. Ideas for Visual Control Equipment Elements “Inspected” marks and match marks Color-coding (blue) on bolts reserved for adjustment by maintenance personnel only Color-coding (yellow) on holes that do not require bolts 28 © Operational Excellence Consulting. All rights reserved.

29. Visual Control Examples Gage labels Adding a simple gauge label enables any employee to easily detect abnormalities at a glance and at a distance. Without the label, only a trained inspector would know if the temperature or pressure setting is correct. Oil level indicators Placing a green and red striped label behind the oil sight tube helps operators quickly detect when oil levels are too high or too low. Source: Adapted from Brady 50 Lean Visuals Pocketbook 29 © Operational Excellence Consulting. All rights reserved.

30. Operational Excellence Consulting is a Singapore-based management training and consulting firm specializing in enhancing business performance and effectiveness. We focus on maximizing customer value and minimizing waste through strategic adoption of Design Thinking and Lean management practices. For more information, visit www.oeconsulting.com.sg 30 © Operational Excellence Consulting. All rights reserved.