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Version 2.0 * Autonomous Maintenance Stage 1 Autonomous Maintenance Step 1 Goals Target groups Practical advice Forms Check lists The 7 steps of AM Reasons for doing AM Methods and tools Autonomous Maintenance Definition of AM Version 2.0 * Autonomous Maintenance Stage 1 Autonomous Maintenance Version 2.0 * Autonomous Maintenance Stage 1 Situation prior to TPM® Tasks of maintenance Tasks of manufacturing - Cleaning and lubrication Maintenance and inspection Preventive Maintenance - Overhaul - Repairs (after breakdowns) Cleaning Reacting to unplanned stoppages - Production Situation after the introduction of TPM® Tasks of maintenacne Tasks of manufacturing Preventive Maintenance Condition-based Maintenance - Overhaul, Improvements - Training of operators - Repairs (after breakdowns) Cleaning, maintenance, inspection, lubrication - Production Change of responsibilities through AM Version 2.0 * Autonomous Maintenance Stage 1 Goals of the Autonomous Maintenance (1) Increasing machine / equipment efficiency through timely maintenance, servicing, and by carrying out improvements, whereby focus is given to the role of the machine operator. Machine / equipment efficiency is positively influenced by: Restoring desirable machine / equipment conditions (Step 1) Improving machine / equipment conditions (Step 2) Maintaining improved machine / equipment conditions (Step 3) Version 2.0 * Autonomous Maintenance Stage 1 By indroducing Autonomous Maintenance, the degree of responsibility assumed by operators concerning their own operational processes is steadily increased. Here a comparison between private and corporate maintenance activites: Tyre pressure Coolant Oil level Fuel Cleanliness Light Cleanliness Tools o.k? Filter clean? Cooling agent available? Sufficient lubrication? Private activities: Corporate activities: Goals of Autonomous Maintenance (2) Version 2.0 * Autonomous Maintenance Stage 1 Having received education and training within the scope of Autonomous Maintenance, operators can independently perform certain maintenance tasks and smaller repairs. Change tyre Check tyre pressure Change spark plugs Refuel Refill coolant Change lamp Refill hydraulic oil Change chuck Change filter Tighten loose screws Private activities: Corporate activites: Check and change coolants Check service points Goals of Autonomous Maintenance (3) Version 2.0 * Autonomous Maintenance Stage 1 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 Version 2.0 * Autonomous Maintenance Stage 1 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 7 Steps of Autonomous Maintenance Version 2.0 * Autonomous Maintenance Stage 1 Cleaning = Inspection! Version 2.0 * Autonomous Maintenance Stage 1 Cleaning = Inspection! Version 2.0 * Autonomous Maintenance Stage 1 Flow diagram initial cleaning 1. Step Create cleaning and lubrication plans 2. Step Preparatory discussion by the team Distribution of the cleaning tasks Preparation of a list of abnormalities 3. Step Initial cleaning Lubricate according to plan Marking and registration of abnormalities 4. Step Compile maintenance plan Correction of abnomralities - Regular cleaning and lubrication Autonomous Maintenance Step 1 Initial cleaning of the machines and equipment Version 2.0 * Autonomous Maintenance Stage 1 Example: Cleaning plan object: Automatic lathe 03 clean protective covers with rags clean bed track guide with brush wipe off glass of oil-level gauge with rags wipe off hydraulic system with rags remove chps from drip tray and clean with hand-brush Autonomous Maintenance Step 1 Basic cleaning of the machines and plants clean water container with steam jet cleaner Version 2.0 * Autonomous Maintenance Stage 1 Autonomous Maintenance Step 1 Basic cleaning of the machines and plants Example: Checklist for cleaning materials Object: 03 Type: Automatic Lathe Tools: Screw driver Allan key Spanner Cleaning Materials Rag Cleaning detergents Broom Dustpan & Brush Utensils: Brush Scraper Water Tank Steam Jet Cleaner Vacuum Cleaner Protective Clothing: Overalls Safety Glasses Rubber Boots Gloves Version 2.0 * Autonomous Maintenance Stage 1 Autonomous Maintenance Step 1 Basic cleaning of the machines and plants Example: Cleaning plan for equipment surroundings: Automatic lathe 03 03 MIN MAX MIN MAX MIN MAX Trolley Trash can Well-cleaned floor Test and measuring tables Tools Pallet Wire baskets Workbenches Jigs Version 2.0 * Autonomous Maintenance Stage 1 Object: 03 Designation: Automatic lathe Measuring station Are the measuring instruments located at the correct place? Are the measuring stations clean? - Are all documents up to date? Defects/ rework Do the containers stand at the correct place? Are the containers clearly marked? Materials allocation Are all materials found at the work- statíon in the correct quantity? Are pallets, containers in a tidy condition? Disposal Are the trash cans at the correct places? Have the trash cans been emptied? Have all ashtrays been emptied? Are chip containers and trash cans in order? Is emulsion container clean? Work area around the machine Are the markings still visible? Is everything located at the intended place? - Is the floor clean? Example: Check list for the surroundings of the machine Autonomous Maintenance Step 1 Basic cleaning of the machines and plants Version 2.0 * Autonomous Maintenance Stage 1 Autonomous Maintenance Step 1 Basic cleaning of the machines and plants Example: Schematic plan for lubrication, automatic lathe 03 2 1 4 3 Version 2.0 * Autonomous Maintenance Stage 1 Autonomous Maintenance Step 1 Basic cleaning of the machines and plants Object: 03 Type: Automatic Lathe Mechanical systems: Secure metal covers Tighten hydraulic connectors Tighten pneumatic connectors Replace missing screws Remove chips from moving parts (do not use pressurized air) Check pneumatic hoses for leaks Identify and eliminate leakage Pay attention to excessively loud noises Visually check all conveyors and transport belts Visualyl check all rubber seals on doors and windows Check servicing points Elektrical systems: Change filter Secure loose cables Check correct fitting of limit switch Check that all appliances are properly fastened Check function of machine lighting Check control lights Version 2.0 * Autonomous Maintenance Stage 1 Autonomous Maintenance Step 1 Basic cleaning of the machines and plants Countermeasure: Removal of abnormalities 1. Marking of abnormalities with colored small cards 2. Register abnormalities 1.Hydraulic pipe leaky 2 Sheet metal bent 3. Lamp defectively 3. Remove abnormalities Activity plan Nr.01 Current condition: Hydraulic pipe leaks Action: Seal hydraulic pipe Order: Date: 4. Check measures Abormalities to be corrected: 1. Seal hydraulic pipe Order done: 04 / 00 2. Straighten sheet metal 05 / 00 3. Replace lamp 05 / 00 Clark Smith Miller Initial cleaning of the machines and plants Version 2.0 * Autonomous Maintenance Stage 1 Autonomous Maintenance Step 1 Basic cleaning of the machines and plants Example: Auditing questionnaire for Step 1 of the Autonomous Maintenance clear 1 3 4 5 6 7 8 9 10 No. . 2 Items to check Points Are cleaning plans and check lists for initial cleaning of the machine present and complete? Are all cleaning tools and agents contained in the check list present at the work station ? Have unnecessary items, jigs, are tools etc. been removed from work station and its surroundings? Has the machine been cleaned, including protective covers and supplementary jigs? Are the cooling agent (emulsion) and the coolant tank in a normal condition? Taking into account condtions of operation, is the work station and its surroundings free of contamination, dust, oil, fat, and chips? Are lubrication plans and check lists for lubrication available at the machine? Has the machine been serviced correctly according to the lubrication plan? Has the machine been inspected according to the inspection plan, and have abnormalities been marked with coloured tags? Have all operators involved in TPM activities been trained in Step 1 of Autonomous Maintenance, and has this been documented? 7
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