Autonomous Maintenance. Workshop (Part 2)
 

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My trainings

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As I suggested last time, I will continue now the training about TPM. Let's see the second day happenings.


 Autonomous Maintenance Workshop

(Part 2)

Step 2
  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
 
 
 
Step 2 / Eliminate leaks
 


 
 
Step 2 / Access to lubrication points
 
Civiemme stacker
 
47 Grease nipples situated all around stacker some inaccessible
 
 
 
Step 2 / Easier to Check
 
 
 
 
Step 2 / Easier to maintain
 
 
Now let’s go and do it
 
Step 3
  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
 

 
Visual Standards
  Objective    
   
To make it EASY
to do things right
       
    and DIFFICULT
to do things wrong
Visual Techniques
 
  • Markings on Gauges (Red and Green)
  • Level Indicators on Oil Bottles
  • Inspection Windows for Moving Parts
  • Positional Markings of Nuts and Bolts
  • Tagging Open and Closed Valves
  • Direction of rotation of motors
  • Marks for alignment
  • Highlighting Critical Areas for Cleaning, Checking and Lubricating
  • Colour codes for Lubrication
  • Sequence Numbers on Inspection Checks
  • Photographs of Equipment Standards
  • Shadow Boards for Spares and Tools
  • Standard Operating Procedures and Instructions for Correct Operation
  • One point lessons
  • Charts and Graphs to show Progress
Step 3 / Visual standards
   
Marking on gauge  
  
 
 
Check sequence number  
   Marking on gauge  
 
  Use of 1 point lessons to show where belts go on machine
 
  Inspection windows and simple gauges  
  Light colour
machinepaint
 
Open machinefor
easy checking & access
 
Monitoring oil
levels
MIN - MAX
 
Hydraulic oil
Temperature
monitoring
Air pressure is
Colour marked
 
 
 
 
 
 
 
Service checklist
Checkpoint numbers
 
 
Step 3 / Clean and check standards
   
Step 4
  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
Step 4 / Training
   Train employees in Autonomous Maintenance
 
Build knowledge of the machine
 
Construction
 
Operation
 
Build skills to perform tasks
One Point Lessons
  Contain content which can be delivered in 15 minutes or less
  Are highly visual
  Are an essential aid to communication for Operators,           Maintainers, Managers and Support Staff
  Address the main stages of the learning process:
 
Explain          (Awareness)
Demonstrate  (Understanding)
Practice         (Skill Development)
Confirm          (Competent to Train Others)
Step 4 / Training material
 
Training
 
Example
Step 4
  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
Autonomous Maintenance
 Workshop
The End
 
 
 
Best regards,
 
   Kovács Zoltán
Owner KZK Solutions
 
Link to the video

 


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