Autonomous Maintenance. Workshop (Part 1)

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Last time I shared already information about maintenance. I presented also my Access database to handle this activity. Now go further, let's see the TPM as a part of lean manufacturing. It is much more then maintenance it is a kind of thinking.

I will show it in two parts in a frame a workshop.

 Autonomous Maintenance Workshop (Part 1)

  • Learn about TPM and Autonomous Maintenance
  • Do Autonomous Maintenance on a “equipment”
  • Refurbish the “equipment”
  • Improve ease of keeping in good condition
  • Develop standards to keep in good condition
  • Have fun – learn something
  Total Productive Maintenance (TPM)
  • System that links all maintenance in a Company
  • Is aimed at improving productivity and profit
Autonomous Maintenance (AM)
  • Operator involvement in equipment care
  • Cleaning, checking and lubricating equipment
  • Simple routine Maintenance tasks
Planned Preventative Maintenance (PPM)
  • Engineering routine maintenance
Predictive Maintenance
  • Use of techniques such as vibration analysis and thermographics to predict when equipment will fail
Maintenance Attitudes Traditional Vs TPM?
Fix it when it breaks down

Keep equipment in good condition for its full life by properly maintaining it
TPM - Roles and responsibilities
Measuring Maintenance Performance
How do we measure operational performance?

Benefits of TPM

  What do You think the benefits could be?  

  • Maximise efficiency
  • Improved reliability and productivity
  • Economic use - total service life
  • Improved OEE
  • Increased capacity
  • Flexibility
  • Improved profitability
  • Better working environment
  • Training in new skills
  • Increased utilisation of skills
  • Practical and effective team-working
  • Less frustration
  What’s different about Autonomous Maintenance?
  Improved operator/engineer understanding of equipment and process Shared objective to improve OEE by:
  • Restoring equipment to optimum condition
  • Keeping equipment in optimum condition
  • Resolving any problems
  • Establishing best practices
  • Improving equipment over time 
  • Changing roles of operators and engineers
  • Improved teamwork between operators and engineers

How important is the Operator?
  It is the Operators who can sense the condition of equipment and prevent it from breaking down.
  • Without this co-operation maintenance cannot be carried out effectively.
  • (It is important that we listen to and act on what the operator is reporting)
How important is the Operator?
    What checks could you do on your car  
Operator checks - car

Maintenance Responsibilities

Clean the car
Check for scratches
Check for stone chips
Check tyre wear

Check tyre pressure
Check Oil level
Check coolant



10.000 km service
Engine diagnostics


Key Learning Points
  We need to be aware of the Hidden Cost caused by the ‘quick fix’ approach to equipment problems
Use our senses to detect equipment problems
Our operators and engineers are the experts so they can (with training) decide how to run and maintain equipment in the best way
  We must improve Teamwork between them
Together we can Measure the benefit, set and maintain OptimumCondition and continuously  Improve our equipment
Equipment Condition Introduction
  What do you think are the main causes of equipment breakdowns?  
Why is dust and debris so important?
  Relationship between problems and accelerated deterioration
  • Natural Deterioration - Things deteriorate naturally as they are used properly
  • Accelerated Deterioration - Things deteriorate through outside influences
The two sources of accelerated deterioration
  • Equipment Based – No prevention of the causes of Dust, Dirt and other Contamination
  • Operator Based  -  Basic conditions not maintained such as Cleaning, Checking and Lubricating plus Human Errors
The 4 steps of Autonomous Maintenance
  Train everyone in the new standards
  • Get everyone to follow the standards
Create standards
  • Clean, Check and Maintain
  • Visual standards
Make it easier to Clean, Check and Lubricate
  • Eliminate/Reduce sources of dirt and debris
  • Eliminate leaks
Get equipment back to good condition
  • Set initial Clean, Check and Lubrication standards
  • Tag defects and eliminate defects
  Before the workshop the break down the equipment into sections.
Use the equipment and equipment manual to do this
Preparation Criticality assessment
  Break each section down to key component or assembly level
Estimate the probability of failure, severity of failure and detection of failure before it happens.
Use this to prioritise the condition appraisal
  Preparation Criticality assessment  
Legend for Criticality
    This allows priorities to be set when
assessing the condition of the equipment
  3 Happens frequently
  2 Happens occasionally
  1 Happens infrequently or never

  3 Complete loss of function
  2 Partial loss of function
  1 No loss of function

  3 No detection before failure
  2 Some chance of detection before failure
  1 Easy to detect before failure
Step 1
   Get equipment back to good condition
  • Set initial Clean, Check and Lubrication standards
  • Tag defects and eliminate defects
Step 1 / Understand the machine
    Go to the machine and find out how it works  
    Draw the machine – how it functions  
Step 1 / Cleaning is Checking
Step 1 / What we are looking for
  With the machine running
  • Abnormal noises
  • Air leaks
  • Sensors working
  • Machine functions correctly
  • Belts run in line
  • Smooth operation
  • Interlocks work
  • Stop buttons work (where practical)
With the machine stopped and isolated
  • Dirty or neglected equipment (e.g. Filters)
  • Disconnected hoses
  • Missing or damaged guards
  • Missing or loose nuts and bolts
  • Leaks  - Hydraulic and lubricating oil, water, ink
  • Metal filings
  • Worn/damaged belts
  • Seized or rough bearings
  • Gauges and lubrication points – hidden, inaccessible
  • Worn chains, sprockets, pulleys, drive belts, shafts, etc.
  • Broken/damaged electrical connections and cables
  • Signs of things rubbing – where they shouldn’t
  • Anything else that doesn’t look right
Tapes that are incorrectly assembled 

Gauges that are difficult to read
Clogged filters

Broken or damaged parts
Correct tension on chains and belts
Step 1 / Conditional appraisal
  Complete Condition appraisal based on Criticality assessment and findings during initial clean and check
Step 1 / Refurbishment plan
Complete a refurbishment plan detailing work done during the workshop and work needing to be completed after the workshop
Culture of keeping equipment in good condition
In the next part we continue our series on getting to know the issue is now under way.
Best regards,
   Kovács Zoltán
Owner KZK Solutions
Link to the video


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