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8/18/2019 Autonomous Maintenance Review - Chapterss 1-6
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AutonomousMaintenancefor Operators
Chapter 1Becoming Equipment
Conscious Operators
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Autonomous Maintenance
• Autonomous = independence
• The activities designed to
involve operators inmaintaining their own
equipment
• AM helps operators become
equipment conscious
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Equipment Conscious Operators
• Equipment ConsciousOperators are more than
finger pointers
• Ability to discoverabnormalities
• Ability to correct
abnormalities
• Ability to set optimalequipment conditions
• Ability to maintain optimal
equipment conditions
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Ability To Detect Abnormalities
• t!s easy to identify
" #unctional brea$downs
" %efects
• Operators need to be ableto recogni&e abnormal
conditions before the
machine brea$s down
" 'ounds " 'ights
" 'mells
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Ability To Correct Abnormalities
& Restore Function
• (nd essential s$ill ofan EquipmentConscious Operator
is the ability to correct
• Even if we can!t fi) it*
we must be able toclearly e)plain whathappened
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Ability To Set Optimal
Equipment Conditions
• +rd essential s$ill of an
Equipment Conscious
Operator is the ability to setconditions and standards
• 'tandards should allow you to
determine* quantitatively* if theequipment is functioning
normally
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Becoming Equipment
Conscious Operators
• '$ill ,evel -. /ecogni&ing%eterioration 0 mprovingEquipment to 1revent t
• /ecogni&ing that deterioratedequipment conditions are aproblem
• Mastering the basics of
equipment improvement• Encourages operators to
treat their machines aspartners
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Becoming Equipment
Conscious Operators
• '$ill ,evel -.
• 2ands3on cleaning*inspection 0 lubrication
leads to discovery ofdeterioration
• 2ands on also allows usto discover simple ways
to prevent recurringproblems
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Becoming Equipment
Conscious Operators
• '$ill ,evel (. 4nderstanding Equipment'tructure 0 #unction
• 4nderstanding vitalmechanisms of themachine and $eepingthem running flawlessly
• Mechanical %iagrams 0,ubrication Maps toillustrate where attentionis needed
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• '$ill ,evel +. 4nderstanding TheCauses of 5uality %efects
• Operators learn to thin$logically about howdefects occur
• Operators monitor defect
trends as it pertains toT1M activities
Becoming Equipment
Conscious Operators
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Becoming Equipment
Conscious Operators
• '$ill ,evel +.
• ,evel ( Operators focus on
preventing malfunctions thatcause brea$downs
• ,evel + Operators focus onpreventing malfunctions that
cause deterioration and
quality defects
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Becoming Equipment
Conscious Operators
• '$ill ,evel 6. 1erforming/outine /epairs
• #irst learn how equipment
functions• 'econd how to find brea$down
abnormalities
• Third how to find qualityabnormality
• ,evel 6 we learn simpledisassembly and repair " Torque bolts properly
" Align pulleys 0 gears
" Changing 7earings
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Capter ! Summary
• Autonomous Maintenance
is to equip operators with
s$ills and abilities to help
prevent machinebrea$downs and quality
defects8
• There are 6 '$ills in
becoming EquipmentConscious Operators
• Companies and people
grow together
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AutonomousMaintenancefor Operators
Chapter 2
Cleaning is Inspection
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"nitial Cleaning "s Te
Foundation O# AM
• Cleaning is nspection
• nspection is finding
problems
• 1roblems demand
restoration to prevent
recurrence
• nitial Cleaning could bethe most important step
in AM
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$en %ou Find A roblem' Tag "t(
• /emoving years of gun$ will
reveal problems
• Attach a tag to each problem
you e)pose so it won!t beforgotten
• #i) problems as soon as
possible
• %evelop a plan for resolvingproblems that cannot be
addressed immediately
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Common roblems
'tatic 0 %ynamic 1roblems•%irt 0 grime
•,ea$s or contamination
•Missing parts
•9arping or wear •/ust
•Off centered parts
• Abnormal movement
•E)cessive vibration
•4nusual sound or heat
•%iscoloration
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Sample "nspection
Cec)list #or a *ydraulic +nit
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Sample "nspection
Cec)list #or a *ydraulic +nit
!, -oo) s the hydraulic unit dirty
with chips or cutting oil:
s oil lea$ing from pumps*solenoids valves* etc8:
Are oil level gauges clearly
visible:
s there the right amountof hydraulic oil:
Are the inlet caps on tight:
S
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Sample "nspection
Cec)list #or a *ydraulic +nit
., -isten Are there any strange
noises from the pumps*
motors* solenoids valves*
plumbing or any other
machine elements8
S l " i
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Sample "nspection
Cec)list #or a *ydraulic +nit
/, Touc Are there any unusual heat
or vibration from pumps*
motors or solenoid valves:
Are loc$ nuts coming
loose:
2as the oil been wiped off
to confirm lea$s: %o hoses cross or touch
one another:
S l " ti
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Sample "nspection
Cec)list #or a *ydraulic +nit
0, Disassemble Are there any signs of
wear in motor or pumps
couplings: Are the vents on oil inlet
caps in good condition:
Are oil inlet overflows
bro$en or dirty:
2as dirt accumulated
inside of tan$s:
S l " ti
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Sample "nspection
Cec)list #or a Dri1e System
S l " ti
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Sample "nspection
Cec)list #or a Dri1e System
!, -oo) 2ave chips or cutting oil
contaminated the motor or
bra$e:
Are belts wobbling or at the
right tension:
s the bra$e!s oil3level
gauge readily visible: Are belts and pulleys
shielded by safety guards
that permit easy chec$ing:
S l " ti
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Sample "nspection
Cec)list #or a Dri1e System
., -isten Are there any strange
noises ;whining* groaning*
or sounds of slippage< fromthe motor* bra$e* belts or
chains:
S l " ti
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Sample "nspection
Cec)list #or a Dri1e System
/, Touc $ile "n Operation s there vibration from the
motor or bra$e:
0, Touc $ile O##
Are the volume and color of
oil satisfactory:
Are safety guards fastenedsecurely:
Are the motor and bra$e
mounting bolts tight:
S l " ti
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Sample "nspection
Cec)list #or a Dri1e System
2, Remo1e Co1ers & 3eri#y Are belt tensions
satisfactory:
Are belts or pulleys worn:
Are the motor and the
bra$e properly aligned:
s there debris in the motor
cooling fan:
s there any debris in
bra$e lubricant:
Cl i M ti t l T T )
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• Machines will get dirtyagain
• Through deep cleaning
and detection* we will
want to find ways to $eep
the machine from getting
dirty
• This motivation will leadto ideas and better ways
to contain debris to
eliminate cleaning
Cleaning Moti1ates eople To Ta)e
Action & Care #or Macines
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Tips For Cleaning
• %on!t be afraid to get yourhands dirty
• %on!t ust surface clean
• Clean hard3to areas
• %on!t ust clean the main
body of the machine
" Conveyors* gauges* electrical
cabinets• #ocus on where and when
the contamination begins
• %on!t do the ob halfway
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Tips For "nspection
• %on!t stop at obvious problemsyou can see
• ,oo$ for loose fastenings*
vibrations* abnormal
temperatures• ,oo$ for worn pulleys and belts*
loose chains and worn
sproc$ets
• #ind sources of air and oil lea$s• Are cleaning* lubrication 0
inspection points easy to
access:
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Capter . Summary
• nitial cleaning is the heart of AM
• nitial cleaning means cleaningall static and dynamic
problems• 9hen tagging abnormalities*
the person applying the tagshould be the one to remedyand remove it
• The more we clean* the morewe will want to find ways to$eep equipment from gettingdirty again
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Autonomous
Maintenancefor Operators
Chapter 3
Using Localized Containment
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$at is Accelerated Deterioration(
>atural %eterioration
•2appens whether or not
equipment if used correctly
Accelerated %eterioration
•Caused by failure to do
maintain our equipment
•>eglecting a machine!s basic
needs
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Containment
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Te Trouble 4it -arge Enclosures
• Chips* oil* wood* wet3typeprocesses are leading cause of
Accelerated %eterioration
• 4se of machine enclosures are
used to control debris• 9hat are some problems with
large machine enclosures:
" Enclosures do nothing to prevent
actual deterioration " Ma$e maintenance harder
" Complicate changeovers
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Te oint o# Containment
• 2ow should we contain ourdebris:
• 'mall locali&ed guards that
cover the debris at the
source
• 7ring guards close together
as possible to contain the
debris and ma$e it easy toclean
• Tis is Step . o# AM
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• Chec$ whether to coolant isconcentrated on the cutting
point
• f its not* scatter gets worse*
tool life shortens and wor$piece finish is poor
• 4nderstand the direction*
angle* volume and speed of
scattered material
• Chec$ the shape and si&e of
built in guards* see if they can
be improved
Tips #or Containment
Continually "mpro1ing
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• The operator $nows the mostabout the scatter of debris
• Operators with the help of
Maintenance should ?home
ma$e@ covers to testcontainment efforts
• The team should study the
guard* its effectiveness*
adust the design and correctthe problems
• 7uild a long term guard after
corrections have been made
Continually "mpro1ing
Containment
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Bene#its o# -ocali5ed Containment
• Accelerated deteriorationstops because dirt and grime
don!t penetrate to critical
functioning parts
• Cleaning can be performedquic$ly
• ,ubrication 0 inspections
become easier
• 'etups go quic$er becausethe machine is clearer and
not obstructed by large
guards
E l Milli M i 8 d
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• Operators originally made bo)containment guards
• %ebris still piled up
• Operators became frustrated and so
they ust let the debris pile up and
then clean it at the end of the shift "which too$ + minutes per day
• ,ubrication tan$ was filled with
cutting debris and caused a
brea$down• Team then made rubber curtain type
shields
E6ample7 Milling Macine 8uard
Decreasing Brea)do4ns & De#ects
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• ,ocali&ed containment isessential
• >atural deterioration will replace
accelerated deterioration
• 9hen you ta$e the time to fi) itat the source* you will reduce
future brea$down
• STO "T999
• 9hat are some e)amples oflocali&ed containment at your
plants:
Decreasing Brea)do4ns & De#ects
$it -ocali5ed Containment
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Capter / Summary
• Accelerated deterioration happens as a results
from failure to do something you should
• Beeping the wor$ area clean is an important
concept in reducing accelerated deterioration• Two types of containment are shield3type and
bo)3type guards
• ,ocali&ed containment is a more effectivemethod for controlling debris than large shields
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Autonomous
Maintenancefor Operators
Chapter 4
Lubrication Management
or the !hop loor
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$y -ubricate(
• D of brea$downs of moving parts
happen due to poor lubrication
• 9hat are some reasons lubrication
fails:
• #ailure to adhere to correct
lubrication standards
• Absence of lubrication standards
• 4se of wrong standards
• Fetting rid of lubrication problems
starts by never running equipment
without lubrication standards
$at is -ubrication
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$at is -ubrication
Management(
-ubricating Equipmentcorrectly and reliably
• According to use
•9ith proper lubricant
• At designated inlets
• At specified times
• At specified amounts
•9hat do we have to have to
ensure proper lubrication:
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• +sing only te speci#ied lubricants recommendedby te OEM 4ould require a lot o# stoc)
• More lubricants increases te ris) o# grabbing te4rong lubrication o## te sel#
8rouping -ubricants
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8rouping -ubricants
To group lubricants7•Ma$e a list of lubrication brands
and types in use
•Froup lubricants that have
similar viscosity
•#or each group reduce the total
number of lubricants $ept on
hand
•4se multipurpose lubricants that
will wor$ on multiple machines
;chec$ wGOEM!s<
Adding -ubricants
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Adding -ubricants
At Te Rigt Time
• 1roper lubrication intervalsare crucial
• Create ,ubrication
'chedules
• f the OEM gives no
guidance on lubrication
intervals* or your machine
doesn!t have an operating
manual
" Must set sensible standards
and verify lubrication
through trial
Adding Te Rigt
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Adding Te Rigt
Amount o# -ubrication
• Too much lubricationcan cause lea$s* lower
viscosity 0 promote
deterioration of thelubricant
• Too little lubrication
case cause friction*
stic$ing and motor burn
out
Operator Responsibilities
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Operator Responsibilities
& -ubrication Tips
• Always $eep the machineslubrication and friction
surfaces clean
• Beel lubrication containers*
tools well organi&ed and clean• Ma$e sure no debris or
moisture gets into lubricants
• %on!t mi) lubricants* unless
required
• ,abel lubrication sites with the
appropriate type and
frequency
D il - b i i C )
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Daily -ubrication Cec)s
• %aily chec$s tell us a story about
normal operating conditions.
• s lubricant getting to the parts
;actually chec$ periodically
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Setting -ubrication Standards
Standards need to include7
•nlet ,ocations
•Method #or Chec$ing
•,ubrication Method
•,ubricant Type
•,ubrication Tools
•Time >eeded To ,ubricate•,ubrication 'chedule
•1erson /esponsible
E i - b i ti St d d
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Easing -ubrication Standards
• Te responsibility o#
mo1ing lubrication to
operator is uge
• Te easier you ma)e it' tebetter te transition 4ill be
• Color code lubrication
types and inlets
• Combine 5er)s to acentrali5ed lubrication
system
3i l M t
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3isual Management
• 3isual Management sould
be used #or lubrication
inlets' containers' tools
and practices7
• Distinguis lubricants o#
di##erence 1iscosities
• Matc inlets 4it grease
guns• Color coding elps
mista)e proo#ing
C t 0 S
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Capter 0 Summary
• 1oor lubrication of moving parts accountsfor D of downtime
• The only way to Hero %efects and Hero
%owntime is a standardi&ed ,ubricationManagement 'ystem
• Consolidate lubricants to reduce the
amount of stoc$
• The right lubricant at the right time is
crucial
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Autonomous
Maintenancefor Operators
Chapter "
Acti#it$ %oards and Meetings
Autonomous Maintenance
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Autonomous Maintenance
& Team Acti1ities
• The goal of AM is for Maintenanceto help develop operators to have
strong machine related s$ills
• 9hat is the most crucial element
to ma$e AM successful• TEAM 9O/BIII
• 9hat does the teams success
depend on:
" 'upport
" #avorable environments
" Motivation
" Ability
$ere does
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$ere does
Moti1ation Start(
Clearly Bnowing.•9hat are we going to do:
;Theme<
•9hy are we going to do it:;Jision<
•2ow far are we going to go:
;Targets<
•2ow are we going to do it:;Method<
$ere does
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e e doesMoti1ation Start(
Clearly Bnowing.•9hat is the sequence and
timing of actions:
;'chedule<•9ho does what: ;/oles<
•9hat results are e)pected:
;Assessment<
T A ti it B d A 8 id t A ti
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Te Acti1ity Board7 A 8uide to Action
• Activity 7oardscommunicate and translate
the Jision
•Clarity is $ey
• At a glance you can see
where you are
• The same approach to a
sporting event can andshould be used at wor$
8i i E t t t T
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8i1ing Encouragement to te Team
• The Activity 7oard shouldalways e)press support for
people and their hard wor$
• Activity 7oards that are
easy to understand will spur
members to $eep up their
efforts ;as long as there is
ownership 0 accountability<• ?Food 9or$@* ?9ay To Fo@
0 ?Atta 7oys@ go along way
Remembering te 8oal
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Remembering te 8oal
Activities should be evaluated.•9ere the goals achieved
consistent with team obectives:
•%id the activity resolve everything
or do problems still remain:•9as anything left undone:
•%id the team run into any
problems:
•9hat is the ne)t step:
+sing Acti1ity Boards "n Meetings
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+sing Acti1ity Boards "n Meetings
• Activity 7oards are an effectiveway of showing what is current
and what needs to be done
• Activity 7oards helps team
members focus meetings on theright issue
• Activity boards can be
supplemented by One 1oint
,essons ;chapter <• Activity boards* meetings and
one point lessons are essential
tools of team activities
:eeping Minutes o# Meetings
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:eeping Minutes o# Meetings
• Minutes provide valuabledocumentation of progress
• After the meeting is over a
document should bedistributed that lists. " %ate 0 time
" Attendees 0 meeting ,eader
" Topics discussed
" %ecisions made
" Actions to be ta$en
Rules For Meetings
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Rules For Meetings
• Time is limited* stic$ to the
point ;par$ing lots<
• The team comes first* focus
on team goals• Beep trac$ of the main points
of the meeting on a board
• 'pea$ with an open mind• ,isten with an open mind
Rules For Meetings
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Rules For Meetings
• %on!t be too formal• %on!t monopoli&e or allow
others to monopoli&e the
discussion
• Avoid tal$ing in vague
generalities
• Accept contrary views
;>emawashi<• E)press your views when
they are fresh
Ten Tips For -eaders
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Ten Tips For -eaders
%uring The Meeting.• At the start of the meeting* write the
scheduled ending time in big letters
• Assign specific people to fill the roles of
facilitator* scribe and activity board
manager
•Fo over the agenda of subects for
discussion and decision
•#or each action decided* confirm and
target completion dates and responsiblepersonnel
•'et the date for the ne)t meeting 0
than$ everyone
Ten Tips For -eaders
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Ten Tips For -eaders
After The Meeting.•1ost minutes on the Activity
7oard and distribute minutes
•4pdate the teams action plan
•/eport to your manager and get
his or her guidance and advice
Capter 2 Summary
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Capter 2 Summary
• Theme* Jision* Targets* Methods*'chedule* /oles and Assessments
• Activity 7oards serve as a guide to the
teams activities and accomplishments• Activity 7oards should be clear and serve
as discussion points for meetings
• Activity 7oards should show at a glance theteams goals* specific problems* actions*
deadlines and results
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Autonomous
Maintenancefor Operators
Chapter &
One 'oint Lessons
$at is a One oint -esson ;O-
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$at is a One oint -esson ;O-
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O- As A Cascading Training Tool
• ts not enough to pass oninformation verbally
• O1,!s capture $nowledge
from team leaders and
members
• O1,!s are short and
focused on a topic that is
frequently discussed• O1,!s put $nowledge into
simple 0 clear form
urposes and ilosopy
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urposes and ilosopy
O1,!s have + 1urposes.•To help sharpen equipment3
related $nowledge and s$ills
and communicate information
about specific problems•To share important information
easily when it is needed
•To improve the performance of
the team
urposes and ilosopy
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urposes and ilosopy
The 1hilosophy of O1,!s.•%evelop and research the
lesson yourself
•The company ma$es up their
own lesson sheets•E)plain them to all team
members
•%iscuss O1,!s openly
•mprove them as needed
Types o# O-=s
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Types o# O- s
Basic :no4ledge -essons7
•4sed to fill in $nowledge gaps
•Ensure team members have
the $nowledge the need for
daily production 0 T1Mactivities
•May focus on. " ,ubrication* nspection
" 'afety Aspects
" '* etc8
Types o# O-=s
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Types o# O- s
E6amples o# roblems7•7ased on problems that are
reoccurring
•,essons are designed tocommunicate $nowledge or
s$ills to eliminate future
problems
•'hould show defect as wellas how it ?should be@
Types o# O-=s
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Types o# O- s
E6amples o# "mpro1ements7•Ensure successful
improvement ideas are widely
used
•llustrates what needs to be
done to prevent or correct
abnormalities
" %escribes the approach " Actions to be ta$en
" /esults of improvement proects
O- Form
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O- Form
• 'hould be customi&ed foryour organi&ations needs
• Might include '* AM*
'afety etc8• O1, should be posted at the
point of use
• ,ong 'O1!s can be
simplified into O1,!s
Tips #or $riting O-=s
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Tips #or $riting O- s
• 7e relevant based on acommon problems the
wor$place is currently
facing
• %on!t ust describe theproblem in words " use
pictures* diagrams etc8
• Ma$e lessons immediately
after a problem hasoccurred and teach if while
its fresh
resenting te O-=s
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resenting te O- s
• As$ people questions and
after the presentation and
follow up on the topic
discussed• /epeat several times ;if
needed< until the issue is
resolved
O- E6amples
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O- E6amples > !!2?!!@
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O- E6amples !!2 !!@
O- E6amples > !!2?!!@
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O- E6amples !!2 !!@
Capter Summary
8/18/2019 Autonomous Maintenance Review - Chapterss 1-6
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Capter Summary
• O1,!s are to be used with Activity 7oardsfor continuous training
• O1,!s are 3-D minute training modules
that can be constructed by any teammembers
• 'hould be made right after a problem has
occurred so the O1, is relevant• 1resent the O1, to the AM team and
encourage feedbac$