Autonomous Maintenance Webinar
During presentations (12:30 13:00) everyone will be muted so that only the presenter will be heard. The presentation will be followed by a Q&A session. Click on the hand symbol to show that you have a question or type your question in the question box. Recording will be made available after the webinar on the Industry Forum website. If you are experiencing any technical problems please call us on 0121 717 6620.
What is Autonomous Maintenance? A process to restore equipment to its optimum condition A process to involve equipment users in the autonomous management of their equipment
Why do we need to restore equipment? Research has shown that between 70% and 95% of equipment failures are due to the forced deterioration of equipment Restoration is the process of removing abnormalities caused by forced deterioration and preventing their recurrence
Why do we need autonomous management? Lean manufacturing require teams to respond to customer demands as quickly and flexibly as possible This is only possible through autonomous management of their processes and equipment
Key AM concepts Forced Deterioration Chronic Losses Sporadic Losses
What is Forced Deterioration? Equipment deteriorates - things wear If we don t maintain and operate equipment properly then it deteriorates faster forced deterioration
What do the effects of forced deterioration look like? Contamination from product or process debris Minor damage - Bent Parts/Tooling, minor cracks Wear and Vibration Leaks - air/water/steam/lubricant Overheating Missing items Loose fastenings Corrosion
Chronic and sporadic losses Failures A failure is the tip of the iceberg! Sporadic Losses (Breakdowns) Hidden abnormalities which result in chronic losses (reduction in performance and quality) Wear, play, slackness, leakage, dust, dirt, corrosion, deformation, adherence of raw materials, surface damage, cracking, overheating, vibration, noise, and other abnormalities Expose hidden abnormalities and prevent quality and functional failures before they happen
A view of equipment loss Poorly managed equipment Deterioration Abnormalities Unnoticed or ignored Chronic losses Sporadic losses Lost availability, performance and quality
The eight steps of Autonomous Maintenance Phase 3 Step 7 Autonomous Management Step 6 - Standardisation Phase 2 Phase 1 Step 5 Autonomous Inspection Step 4 General Inspection Step 3 Create and maintain cleaning, inspection & lubrication standards Step 2 - Eliminate sources of contamination and difficult to clean and inspect areas Step 1 Initial Cleaning Step 0 Preparation
The purpose of the phases Phase 1 Restore equipment Phase 2 Upskill AM teams Phase 3 Develop Autonomous Management
Step 0 - Understand the equipment air injector feed funnel Organisation Machine / Line Date Created By Issue No. Drawings Equipment Function Worksheet Step 0 Worksheet 1 motor Notes Process for developing mechanisms 1. Identify the key mechanisms involved in the investigation (follow the product flow) 2. Study and develop an understanding of function and operatios of the mechanisms 3. Draw diagrams to explain the function and operation 4. Add notes to help explain the function & sequence of operation of the mechanisms
Step 1 Initial Cleaning
Step 2 Eliminate Contamination
Step 2 Eliminate Contamination
Step 2 Ease of Inspection
Step 3 Inspection and Lubrication Select Model Machine AM Team Maintenance staff Managers Trial Lubrication AM Team Maintenance Staff Draft Provisional Standards for Cleaning & Inspection Identify
Step 3 Inspection and Lubrication
Provisional Standard
One Point Lesson
Check Sheet
Implementation Tips Choose a meaningful but manageable pilot: Equipment whose performance is important but not critical Common equipment where lessons learned can be duplicated Small enough to provide resource to follow up on corrective actions target 8 weeks
Implementation Tips (2) Choose a positive team: Good, stable team dynamics with good team leader Previous commitment to improvement activity Good skill balance
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