Total Preventative Maintenance Autonomous Maintenance

Step 0 and 1 (Part 1) Program Initiation

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Revision 1 2014/01/14

TPM Training Schedule

Participants: AIDC Team, Senior Management Team, Production Team.

Aim: To present the fundamentals of Autonomous Maintenance and start

company’s journey through Total Productive Maintenance.

Training Schedule:

Step 0 theory 30 Minutes

Step 0 practical training 1 Hour

Step 1 theory 1 Hour

Step 1 practical training 1.5 Hours

Step 1 closing and findings discussion 30 Minutes

Followed up with daily cleaning and weekly meetings

We all need to work so we can provide our families

But…

Our companies must be productive so they can sustain us.

We want our economy to create wealth and opportunity for everyone

We have competitors knocking on our door.

We need something to guide us, this is where TPM comes in…

Definition: “A structured approach that establishes a corporate culture, that will

maximise production system effectiveness”

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•All individuals in the organization working together.

Productive

•Production of goods that meet or exceed customer’s expectations.

Maintenance

• Keeping equipment and plant in good condition at all times.

We all work together from management to shop floor

Prevent losses and achieve

in the entire production system life

Increase skills development and improve safety

Zero Accidents

Zero defects

Zero Breakdowns

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 Team Members 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”

Team Members become equipment

experts, taking ownership of their

equipment.

Problems that stop or slow the machine can

be eliminated by changing the attitude

of the people – Managers, Operators

& Technicians

Equipment works better, people

work better

People work better, factory works better

Factory works better, people

are happier

Zero Defect & Zero Breakdowns can be attained when

1. Initial Cleaning

2. Counter measures against sources of dirt & difficult

points

3. Develop tentative standards of cleaning,

inspection & lubrication

4. General Inspection

5. Autonomous inspection

6. Standardization

7. Autonomous

Management Stage-3

Standardize maintenance

activities & implement

Autonomous Control

Stage-2

Assessment of the wear on

equipment & Develop activities

to prevent it

Stage-1

Establish Basic Conditions

of the Equipment & Maintain

those conditions

Steps

Levels

0. Preparation Get people motivated

Deficient communication

High Nº of accidents

Lack of interest of the

Team Members

Lack of skills Low operative

efficiency

High # of damages

LOSSES DUE TO BREAK

SMALL STOPS

LOSSES DUE TO SPEED

LOSSES DUE TO SETUP

LOSSES DUE TO DEFECT

LOSSES DUE TO RAW MATERIAL

GHEE, THE MARKERS ARE NOT

GETTING BETTER

LACK OF

INTEREST

DIFFICULTY

TO MAKE OUT

LACK OF

SKILL

“I OPERATE, YOU REPAIR”

PRODUCTION

TEAM

MAINTENANCE

STAFF

“BE GREATFULL THAT I FIXED YOUR MACHINE”

Selfish attitude

Negative attitude

=

+

NON PRODUCTIVE MAINTENANCE

PRODUCTION

Baby Parents Physicians

Machines Maintenance

Take charge of making improvements; on their own & through working with other departments

Carry out repairs

Understand the relationship between equipment condition & quality of the product; i.e. foresee quality issues & recognize the cause.

Identify & correct equipment abnormalities

Understand how the equipment works & identify the causes of abnormality

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.

1s & 2s is a foundation program before the

implementation of TPM

To make the workplace organised and neat, 1S

and 2S needs to be implemented

Team digging in sorting

out their workplaces

Sort:

• Hand Tools

• Gauges

• Equipment Accessories

• Spares

• Cupboards and work tables

Classify necessary & unnecessary tools and equipment around Work

Station

Clear out unnecessary items, take them to salvage area or store

Priority

Frequency of

Use? How to Use?

Low Less than once

per Year.

Throw away.

Store away from

the workplace.

Average At least Once

per Month

Store together

but Off-line.

High Once per Day. Locate at the

Workplace.

Before and After Clearing area

1S (Seiri/Sorting)

Team Member tool cupboard

Team Member cleaning cupboard

2S (Organising)

• Decide the right place for each

necessary item (location)

• Mark the locations by drawing a

boundary around the equipment

to indicate its zone

• Exhibit:

• Equipment Running • Job Change • Tool Change • Break Down

2S (Organising)

1S Sorting

• Classify needed and unneeded items in work area

• Clear out unneeded items in work area

Autonomous Maintenance

• Operator takes ownership of his/her equipment at all times

• Establish basic conditions of equipment

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

Revision 1 2014/01/14

TPM Training Schedule

Participants: AIDC Team, Senior Management Team, Production Team.

Aim: To present the fundamentals of Autonomous Maintenance and start

company’s journey through Total Productive Maintenance.

Training Schedule:

Step 0 theory 30 Minutes

Step 0 practical training 1 Hour

Step 1 theory 1 Hour

Step 1 practical training 1.5 Hours

Step 1 closing and findings discussion 30 Minutes

Followed up with daily cleaning and weekly meetings