Total productive
Maintenance
Autonomous
Maintenance
- Step 0
Safety, Health,
Environmental
TPM in Administration
Quality Maintenance
Early Management
5S
Education and Training
Effective Maintenance
Focussed Improvement
Autonomous Maintenance
Introduction – Total Productive
Maintenance
Definition: “A structured approach that establishes a corporate
culture, that will maximise production system effectiveness”
TPM: Aim of TPM:
• Total – Involvement of all functions and • Prevent losses and achieve:
people at all levels of organisation • Zero Accidents
• Productive – Efficient and effective • Zero defects
utilisation of all resources • Zero Breakdowns
• Maintenance – Keeping the man- in the entire production system life
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
Steps Levels
7. Autonomous Stage-3
Management
Standardize maintenance
6. Standardization activities & implement
Autonomous Control
5. Autonomous inspection Stage-2
Assessment of the wear on
4. General Inspection equipment & Develop activities
to prevent it
3. Develop tentative standards of cleaning, Stage-1
inspection & lubrication
Establish Basic Conditions
2. Counter measures against sources of dirt & difficult
of the Equipment & Maintain
points
those conditions
1. Initial Cleaning
0. Preparation Get people motivated
Example of Implementation
Issues that Impact OEE
Low operative
efficiency GHEE, THE MARKERS ARE NOT
GETTING BETTER
High # of damages
Deficient
LACK OF
communicacition INTEREST
High Nº of accidents
DIFFICULTY
TO MAKE OUT
Lack of interest of LACK OF
the operators LOSSES DUE TO SETUP SKILL
LOSSES DUE TO DEFECT
Lack of skills LOSSES DUE TO RAW MATERIAL
Issues of Prod & Maint.
OPERATOR Selfish attitude
“I OPERATE, YOU REPAIR”
+ MAINTENANCE
STAFF Negative attitude
“BE GREATFULL THAT I FIXED YOUR MACHINE”
= NON PRODUCTIVE MAINTENANCE
TPM View
Baby Parents Physicians
Machines Operators 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
Autonomous Maintenance
• Operator takes ownership of his/her equipment at all times
• Establish basic conditions of equipment
1S Sorting
• Classify needed and unneeded items in
work area
• Clear out unneeded items in work area
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
