CPTB 08 Autonomous Maintenance Step 2 02 SR TR

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Autonomous Maintenance Stage 2
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!
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2
3
4
5
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Autonomous Maintenance Stage 2
Autonomous Maintenance Step 2
Independent 
maintenance 
and servicing of 
machines and 
equipment by the operators 
Prevention of contamination Improvement of servicing
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Autonomous Maintenance Stage 2
Before:
After:
- Initial cleaning of the machine 
- Lubrication according to plan 
- Marking of abnormalities
1. Preparation 
2. Coordination fo activities 
3. Action 
4. Check-up on results 
Abnormalities (e.g. leakages) can only be found if the machine or equipment ist clean! 
Cleaning = Inspection!
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3
2
1
Expiration 
Goal 
Review Step 1 of the Autonomous Maintenance
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Autonomous Maintenance Stage 2
Goals of Step 2
Prevention of contamination - improvement of maintenance 
Determine sources of contamination 
Introduce countermeasures 
Improve maintainablity
These activities show the highest degree of success if teams consist of maintenance men, production operators, and members of the engineering department.
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Autonomous Maintenance Stage 2
Determine and show sources of contamination
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Autonomous Maintenance Stage 2
The 4 elements of the problem solving process
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Autonomous Maintenance Stage 2
Machine/object: 
Topic: 
Goal: 
Datum:
Name:
1. Problem description 
4. Solution evaluation 
2. Cause of problem 
3. Problem solution 
5Why analysis 
Why 
Why
Why
Why
Why
Use of the 
5Why analysis
method 
(see sheet 09) 
Leak of oil vapor 
It is only insufficiently
filtered, condenses, and causes contamination 
Contamination at the filter exit 
Elimination
25.01.
W. Pfiffig
A Maintenance of filters
 at proscribed intervals.
B Replace disposable filters 
 with different type which can be washed 
 (costs, environment).
New Filter
Automat 03
Maintenance intervals 
Week 
Filter cleaning 
04
X
05
06
07
08
09
10
11
12
X
X
It was recognized by observation of the process that 
the filter must be cleanedex/changed every 3 weeks. 
Alternative: Larger filter (costs!) 
Analysis sheet for Autonomous Maintenance Step 2
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Autonomous Maintenance Stage 2
5Why analysis
Why does the machine get dirty? 
Why does oil penetrate through filter? 
Why are the filter mats very dirty? 
Why weren’t they changed in time? 
Why is there no maintenance plan? 
„Because of oil penetrating though filter”
„Because filter mats are very dirty “
„Because they were not changed in time “
„Because there is no maintenance plan” 
„Because prior to the introduction of TPM, nobody gave it any thought” 
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Autonomous Maintenance Stage 2
Example cause effect diagram
Machine/object: 
Topic: 
Goal: 
Datum:
Name:
1. Problem description 
4. Solution evaluation 
3. Problem solution 
Leak of oil vapor 
It is only insufficiently
filtered, condenses, and causes contamination 
Contamination at the filter exit 
Elimination
25.01.
W. Pfiffig
A Maintenance of filters
 at proscribed intervals.
B Replace disposable filters 
 with different type which can be washed 
 (costs, environment).
New Filter
Automat 03
Maintenance intervals 
Week 
Filter cleaning 
04
X
05
06
07
08
09
10
11
12
X
X
It was recognized by observation of the process that 
the filter must be cleanedex/changed every 3 weeks. 
Alternative: Larger filter (costs!) 
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Autonomous Maintenance Stage 2
2. Problem cause
Effect 
Man
Method 
Material
Machine 
Environment
Cause-Effect-Diagramm (Fishbone Diagram)
Moving hands
Design fault
Too hard 
Insufficient 
Insufficient 
point A to B 
illumination
training
All possible causes are examined and evaluated as to their effect (degree of influence on the problem)
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Autonomous Maintenance Stage 2
Cause effect diagram
Booth dirty 
Man 
Method 
Material
Machine 
Environment 
No TPM knowledge 
Cleaning done only sporadically 
Oil filter absorbs
 insufficiently 
Formation of oil vapor
Contamination 
of oil filter 
no maintenance 
plan 
25.01.2001
Team:
K. Klever
W. Pfiffig
D. Nozzle impulse 
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Autonomous Maintenance Stage 2
Sucess by teamwork
Workers/ operators give input on problem occur- ance details 
Technicians/ engineers detail required design changes
Maintenance men carry out design changes 
Together, they work out the improvement proposals 
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Autonomous Maintenance Stage 2
Documentation on the machine board 
11,4 actual condition door leaky,
 cooling water withdraw and lead 
to contamination
Documentation of measures and improvements 
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Autonomous Maintenance Stage 2
Auditing of Step 2
Audit - questionnaires 
1
current No. 
Characteristics 
Points 
2
3
4
5
Have abnormalities found in Step 1 been eliminated? 
Have further abnorma- lities been found and documented in Step 2?
Were measures to take been identified? 
What is the machine condition after Step 2? 
Were operators sufficiently trained and educated? 
Audit
 Step 1 
Audit 
Step 2 
Audit 
Step 3 
Audit
 Step 4 
Audit 
Step 5 
Audit 
Step 6 
Audit 
Step 7