CPTB 09 Autonomous Maintenance Step 3 02 SR TR

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Autonomous Maintenance Step3
Quelle: JIPM (Japan Institute of Plant Maintenance)
7 Steps of Autonomous Maintenance
Independent servicing and maintenance of machines
and equipment by operators
Initial cleaning of machines
and equipment
Prevention of contamination,
improvement of servicing
Standards for cleaning
and servicing
Training of employees to do
independent servicing
Independent servicing
by operators
Standards for 
safeguarding processes
Full application of Autonomous
Maintenance
* Initial cleaning, lubrication
* Marking of defects
* Restoring desirable conditions
* Elimination of leakage
* Improving access to check points
* Eliminating sources of dirt and contamination
* Use of checklists and check plans
* Visual management at machine
* Surroundings (standards for cleanliness and neatness)
* Develop knowledge of machine design
 and functions
* Train skills for independent servicing
* Independent servicing using
 check lists and maintenance plans
* Deepen knowledge of
 servicing and corrective
 maintenance
* Full use and continuous improvement
Cleaning is inspection!
1
2
3
4
5
6
7
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Autonomous Maintenance Step3
Autonomous Maintenance Step 3
Standard for cleaning and
servicing
Initial cleaning of machines
and equipment
Prevention of contamination,
improvement of servicing
Standards for cleaning
and servicing
Training of employees for
independent servicing
Independent servicing
by operators
Standards for
safeguarding of processes
Full application of Autonomous
Maintenance
1
2
3
4
5
6
7
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Autonomous Maintenance Step3
Step 1
Step 2
- Initial cleaning of the machine
- Lubrication according to lubrication plan
- Marking of abnormalities 
- Determining sources of contamination
- Elimination of abnormalities found in Step 1
 Countermeasures for the prevention of contamination
 Improvement of maintainability
Goal 
Goal 
Review Steps 1 and 2 of the Autonomous Maintenance
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Autonomous Maintenance Step3
Goals of Step 3
Develop standards, which can
.. prevent the machine from getting contaminated
.. ensure regular maintenance
.. shorten cleaning and inspection times
Improvement 
Time 
Standard
What do we mean by “standards”? 
Status
Quality consciousness 
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Autonomous Maintenance Step3
Ensuring regular maintenance
1
2
3
4
5
6
7
Control console 
Lubricating oil container 
Filtering unit 
Switch box
Hydraulics
unit
Safety catch 
Cooling water basin 
Start
Check-
punkt
Component 
Check
Values 
Control console 
Lamp test
Function yes/no 
Lubricating oil container 
Check oil level
between MIN and MAX 
Filter-mat of cleaning equipment 
Degree of contamination
see samples/comparison 
Switch box
Temperature indication 
max. 28 degrees 
Hydraulic tank 
Check fluid level
between MIN and MAX 
Safety catch 
Check function 
engages 
Cooling water basin 
Check fluid level
between MIN and MAX
Regular maintenance is ensured by 
inspection according to check-lists 
Inspection procedures are defined for 
individual check point :
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Autonomous Maintenance Step3
Structure of a check list
What?
(activities) 
How often? 
(interval) 
By whom ?
(function) 
Responsibility! 
(inspector) 
Time schedule
Name
examine
oil level
examine fixing 
bolts with 
torque wrench 
change oil filters
Mo
Tu
We
Th
Fr
Sa
daily 
X
X
X
X
X
We
1
2
3
4
5
J
F
M
A
M
J
monthly 
X
X
1. half
2. half
half-yearly 
Machine 
operator 
Electrician
Fitter 
Machine operator 
Miller
Scott
Schulz
Clark
examine degree of contamination of air-conditioning system filter
weekly 
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Autonomous Maintenance Step3
Development of standards
The knowledge acquired in AM Steps 1 and 2 is now converted into standards 
Example: Contamination of the fan blades of an electric motor
Current condition 
Fan blades are
 very dirty 
Standard for the 
prevention of 
contamination 
Checklist: The degree 
of contamination of the filter is checked by visual examination.
Cause: Air which is being sucked in extremely dirty 
Air supply 
Filter
Sample for comparison 
Change filters
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Autonomous Maintenance Step3
Short training of standards (One Point Lesson)
For extensive checks it is meaningful to carry out short training courses on the spot. 
Example of a short training topic: Control/maintenance of a compressed air unit 
MIN
MAX
2
3
4
Water trap 
Oiler 
Pressure indicator
Maintenance task: 
 shut off compressed air supply! 
 empty water traps, lower pressure 
 (observe pressure indicators) 
 fill up oil (Tellus C10) observe MIN/MAX level 
 open compressed air supply
 examine operating pressure
 
1
2
3
1
4
Short training 
Service unit
1
Air supply 
open 
closed 
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Autonomous Maintenance Step3
Development of color standards
I. Machines
Machines and machine
 parts
Switch boxes & internal electrical equipment
Switch boxes & external electrical equipment
Mobile parts and grills 
II. Operational areas 
Operational areas
and equipment 
For each segment 
use different shade of blue 
RAL-Nr.
Color name 
9002
grey-white 
2000
 yellow-orange 
2000 
yellow-orange 
2000 
yellow-orange 
5000
5024
Color standard
Content:
I. Machines 
II. Operational areas
III. Transport vehicles 
IV. Floors 
V. Measuring instruments /
 measuring stations
VI. Containers 
VII. Walls 
Liquid substances,
pipes etc..
VIII.
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Autonomous Maintenance Step3
Examples of standards
Hydraulics, pneumatics, liquid media 
Flow direction 
Compressed air 
Water 
Oils, fats 
Cooling agent, waste water 
Lines, pipes, hoses 
Pneumatics hoses 
Hydraulic oil tank 
Pressure ranges 
of pressure gauge 
Shut-off valves 
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Autonomous Maintenance Step3
Standards for lubrication
Example: How can I secure the correct filling of a hydraulic tank by using standards? 
HLP 46
HLP 46
GF 100
GF 100
Standard 1 
marking of
 lubricants 
Standard 2
Marking of oil 
cans
Standard 3
Filler neck 
coloured and 
numbered
Standard 4
Marking of level 
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Autonomous Maintenance Step3
Development of standard for lubrication and oil supply
Lubrication instruction 
1. Creation of a lubrication standard 
2. Marking of oil 
barrels 
3. Marking of oil 
cans
4. Marking of filler necks
5. Lubrication according to plan
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Autonomous Maintenance Step3
Example for standards
Work stations, environment
Change-over
trolley 
Tools 
Measuring instrument 
Utility spaces 
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Autonomous Maintenance Step3
Examples for standards
Technical installations 
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Autonomous Maintenance Step3
Practical examples
Pressure gauges with coloured markings
Mark shows check 
points or mainte-
nance item 
Bright painting of
machine housing 
Open inspection ports on machines 
Monitoring of
fluid levels 
MIN - MAX 
Monitoring 
of hydraulic oil temperature
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Autonomous Maintenance Step3
 Presentation of OEE
 (overall equipment efficiency) 
- Cleaning plan 
- Maintenance plan 
- Analysis sheets 
 Machine layout 
 Improvement programs
 - Other important KPIs
Standard for visualization at the machine 
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Autonomous Maintenance Step3
Auditing Step 3
Audit questionnaire 
1
current NR
Characteristics 
Points 
2
3
4
Have standards been created and are they followed? 
Have check lists for preventive mainte- nance been created? 
Have all important points been marked? 
Are the operators sufficiently trained? 
Audit
Step 1
Audit
Step 2
Audit
Step 4
Audit
Step 5
Audit
Step 6
Audit 
Step 7 
Audit
Step 3