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1、Autonomous Maintenance,Learning Objective,understand the Autonomous Maintenance performance expectations for:Program ImplementationProgress MeasurementStages and Steps,Effectiveness of Line Team Meetings,Our line teams meet once a month to review performanceAt these meetings,operators often raise is
2、suesThe meetings could be more effectiveWe need to formalize the agenda and process to capture,prioritize and address problems in accordance with business needs,Topic 2:Autonomous Maintenance Implementation,Implementation Plan Performance Expectation,Identify natural work teams(natural team&equipmen
3、t-based team)Define roles and responsibilitiesIdentify line sponsors(work area Team leader/S&C),line owners(operator with enough knowledge and leadership skills),and support resources(S&C)Conduct small group meetings(Twice a month)Create a project plan(An action plan for each natural team through 7
4、steps),SGM is used to complete any of the following activities:,Review and analyze equipment losses.Review status of action items on Equipment Problems and Defects List.Conduct root cause analysis on a specific problem and develop a recommended action plan.Conduct training on a new topic or reinforc
5、e existing programs(e.g.,equipment,new job responsibility,5S&Visual Workplace,Safety,Quality).Review and refresh SOPs.Capture improvement suggestions.Identify issues that should be elevated as maintenance requests.Review Standard Work Instructions(PPMs,One Point Lessons,etc.).,Problem Tags Performan
6、ce Expectation,Shift,date,individual who found problem Location,System,Equipment,Part IDProblem typeOperation typePossible impactPossible corrective action Root cause,Prioritizing Corrective Actions Performance Expectations,Helps teams identify and act on equipment problemsGroups problems and defect
7、s(Defective Areas,Questions,Sources of Contamination and Inaccessible Areas)Should be completed and updated for each piece of equipment,Topic 2:Review,Develop a 3 year planIdentify natural work teamsIdentify roles and responsibilities for each work teamIdentify sponsors,leaders and support resources
8、Distribute and train on:Problem TagsEquipment Problems and Defects List,Topic 3:Autonomous Maintenance Stages and Steps,Step 3 Standardize cleaning,inspection and lubrication procedures,Step 2 Eliminate contaminant sources and inaccessible areas,Step 5 Operators inspect,clean,lubricate and conduct b
9、asic maintenance,Establish Equipment Basic Condition,Step 7 Operators participate in continuous improvement activities,Step 6 Operators are responsible for some aspects of the physical organization and management of the workplace,Step 4 Train operators to conduct daily inspection and basic maintenan
10、ce,Step 1 Complete initial deep cleaning,Stage 1:Establish Basic Equipment Condition,Step 3 Standardize cleaning,inspection and lubrication procedures,Step 2 Eliminate contaminant sources and inaccessible areas,Step 5 Operators inspect,clean,lubricate and conduct basic maintenance,Establish Equipmen
11、t Basic Condition,Step 7 Operators participate in continuous improvement activities,Step 6 Operators are responsible for some aspects of the physical organization and management of the workplace,Step 4 Train operators to conduct daily inspection and basic maintenance,Step 1 Complete initial deep cle
12、aning,Step 1:Initial Deep Cleaning Performance Expectation,Training is the first stepAllows for close inspection of the equipment and its partsCan quickly distinguish abnormal operationUnderstand business impact,Step 1:Initial Deep Cleaning Performance Expectation,continued,Problem IdentificationFor
13、m teams for specific equipmentEnsure that the team understands cleaning is inspection,inspection leads to defect detection,and detection leads to correction of defectsFollow safety rulesUse the Equipment Problems and Defects List and Problem Tags,Step 1:Initial Deep Cleaning Performance Expectation,
14、continued,Problem ResolutionPrioritize opportunitiesAddress questions promptlyUpdate the Equipment Problems and Defects ListEquipment Condition(Initial Cleaning)Conduct for all equipmentInspect for missing or loose parts or components,Step 2:Eliminate Contaminant Sources Performance Expectation,Iden
15、tify and eliminate sources of contaminationIdentify and eliminate inaccessible areasPrioritize corrective actions based on business impact,Step 3:Standardize Procedures Performance Expectation,Design Standard Work Instructions(SWIs)for cleaning,inspection and lubricationUse SOPs,One Point Lessons an
16、d Process Picture Maps(PPMs)Use visual aids to communicate procedures,Stage 2:Daily Inspections and Basic Maintenance,Step 3 Standardize cleaning,inspection and lubrication procedures,Step 2 Eliminate contaminant sources and inaccessible areas,Step 5 Operators inspect,clean,lubricate and conduct bas
17、ic maintenance,Establish Equipment Basic Condition,Step 7 Operators participate in continuous improvement activities,Step 6 Operators are responsible for some aspects of the physical organization and management of the workplace,Step 4 Train operators to conduct daily inspection and basic maintenance
18、,Step 1 Complete initial deep cleaning,Step 4:Daily Inspection and Basic Maintenance Performance Expectation,Operators should understand how the equipment functionsBasic lubricationMachine elements(fasteners)PneumaticsHydraulicsElectrical systemsPower transmission drivesTrain operators in basic main
19、tenance,Step 5:Operator AccountabilityPerformance Expectation,Select maintenance tasks should be moved from maintenance to operationsCompare tasks completed by operators and mechanicsAgree to those that can be movedDevelop SWIs(Standard Work Instruction),Stage 3:Drive Continuous Improvement and Qual
20、ity,Step 3 Standardize cleaning,inspection and lubrication procedures,Step 2 Eliminate contaminant sources and inaccessible areas,Step 5 Operators inspect,clean,lubricate and conduct basic maintenance,Establish Equipment Basic Condition,Step 7 Operators participate in continuous improvement activiti
21、es,Step 6 Operators are responsible for some aspects of the physical organization and management of the workplace,Step 4 Train operators to conduct daily inspection and basic maintenance,Step 1 Complete initial deep cleaning,Step 6:Operator OwnershipPerformance Expectation,Train operatorsDevelop SWI
22、sBudget timeConduct formal meetings,New responsibilitiesSpare Parts Management(nuts,bolts,“o”rings,etc.)Changeover Execution and Improvement5S and Visual WorkplaceMaintain Standard ProceduresOn-line QualityMaintenance Notifications,Step 7:Ownership of Additional Responsibilities Performance Expectat
23、ion,Participate in Continuous Improvement ProjectsMinor MaintenanceImprovement of Maintenance PlansEquipment Redesign/Design,7 Steps divided into 3 stagesComplete deep cleaningEliminate sources of contaminantsStandardize procedures Implement basic maintenance training for operators Select basic main
24、tenance tasks to be moved to operationsEvaluate additional operator responsibilities(QC inspections and changeovers)Incorporate operators in continuous improvement discussions to build ownership,Topic 3:Review,Topic 4:Progress Measurement,Progress MeasurementAutonomous Maintenance Metrics,Monitoring
25、 ProgressPerformance Expectation,AM Step Progression ChecklistsNatural team completes self-assessmentWork Area Leader reviews and verifiesSite Leadership certifies,Monitoring ProgressPerformance Expectation,continued,Progress should be communicated and celebratedFocus Factory progression is recogniz
26、ed when 80%of work area achieves requirements,Topic 4:Review,Autonomous Maintenance Step Progress ChecklistsAutonomous Maintenance Metrics:Small Groups Meeting Schedule Adherence(%)Number of Lines with Standard Work(%)Number of Problem Tags Generated(#)Problem Tags Resolved(%)Problem Tags Resolved b
27、y Operators(%),Topic 5:Next Steps and Course Review,Review FP&R Standards and GuidelinesCreate an implementation plan to address the business challenges identifiedIdentify Natural Work TeamsIdentify Line Sponsors,Owners and Support ResourcesCreate Schedule for Small Group meetingsSelect area to implement AM steps,
