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1、Autonomous Maintenance Learning Objectiveunderstand the Autonomous Maintenance performance expectations for: -Program Implementation-Progress Measurement-Stages and StepsEffectiveness of Line Team MeetingsOur line teams meet once a month to review performanceAt these meetings, operators often raise
2、issuesThe meetings could be more effectiveWe need to formalize the agenda and process to capture, prioritize and address problems in accordance with business needsTopic 2: Autonomous Maintenance Implementation Implementation Plan Performance ExpectationIdentify natural work teams (natural team & equ
3、ipment-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
4、 through 7 steps)004-1. A 3-year implementation plan outlining a site-wide approach should be in place to help the plant progress through Autonomous Maintenance activities. SGM is used to complete any of the following activities:l Review and analyze equipment losses.l Review status of action items o
5、n Equipment Problems and Defects List.l Conduct root cause analysis on a specific problem and develop a recommended action plan.l Conduct training on a new topic or reinforce existing programs (e.g., equipment, new job responsibility, 5S & Visual Workplace, Safety, Quality).l Review and refresh SOPs
6、.l Capture improvement suggestions.l Identify issues that should be elevated as maintenance requests.l Review Standard Work Instructions (PPMs, One Point Lessons, etc.).Problem Tags Performance ExpectationShift, date, individual who found problem Location, System, Equipment, Part IDProblem typeOpera
7、tion typePossible impactPossible corrective action Root cause004-2. Problem tags or equivalent means should be used to visually identify problems. Prioritizing Corrective Actions Performance ExpectationsHelps teams identify and act on equipment problemsGroups problems and defects (Defective Areas, Q
8、uestions, Sources of Contamination and Inaccessible Areas)Should be completed and updated for each piece of equipment004-3. Corrective actions should be prioritized based on business impact and tracked to closure using an Equipment Problems and Defects List at each step.Topic 2: ReviewDevelop a 3 ye
9、ar planIdentify natural work teamsIdentify roles and responsibilities for each work teamIdentify sponsors, leaders and support resourcesDistribute and train on:-Problem Tags-Equipment Problems and Defects ListDrive Continuous Improvement & QualityTopic 3: Autonomous Maintenance Stages and StepsStep
10、3 Standardize cleaning, inspection and lubrication proceduresStep 2 Eliminate contaminant sources and inaccessible areasStep 5 Operators inspect, clean, lubricate and conduct basic maintenanceEstablish Equipment Basic ConditionStep 7 Operators participate in continuous improvement activitiesPerform
11、Daily Inspection & Basic MaintenanceStep 6 Operators are responsible for some aspects of the physical organization and management of the workplaceStep 4 Train operators to conduct daily inspection and basic maintenanceStep 1 Complete initial deep cleaningStage3Stage2Stage1Stage 1: Establish Basic Eq
12、uipment ConditionStep 3 Standardize cleaning, inspection and lubrication proceduresStep 2 Eliminate contaminant sources and inaccessible areasStep 5 Operators inspect, clean, lubricate and conduct basic maintenanceEstablish Equipment Basic ConditionStep 7 Operators participate in continuous improvem
13、ent activitiesDrive Continuous Improvement & QualityPerform Daily Inspection & Basic MaintenanceStep 6 Operators are responsible for some aspects of the physical organization and management of the workplaceStep 4 Train operators to conduct daily inspection and basic maintenanceStep 1 Complete initia
14、l deep cleaningStage3Stage2Stage1Step 1: Initial Deep Cleaning Performance ExpectationTraining is the first stepAllows for close inspection of the equipment and its partsCan quickly distinguish abnormal operationUnderstand business impact004-5. Complete initial deep cleaning (Step 1)Step 1: Initial
15、Deep Cleaning Performance Expectation, continuedProblem Identification-Form teams for specific equipment-Ensure that the team understands cleaning is inspection, inspection leads to defect detection, and detection leads to correction of defects-Follow safety rules-Use the Equipment Problems and Defe
16、cts List and Problem Tags004-5. Complete initial deep cleaning (Step 1)Step 1: Initial Deep Cleaning Performance Expectation, continuedProblem Resolution-Prioritize opportunities-Address questions promptly-Update the Equipment Problems and Defects ListEquipment Condition (Initial Cleaning)-Conduct f
17、or all equipment-Inspect for missing or loose parts or components004-5. Complete initial deep cleaning (Step 1)Step 2: Eliminate Contaminant Sources Performance ExpectationIdentify and eliminate sources of contaminationIdentify and eliminate inaccessible areasPrioritize corrective actions based on b
18、usiness impact004-6. Eliminate contaminant sources and inaccessible areas (Step 2) Step 3: Standardize Procedures Performance ExpectationDesign Standard Work Instructions (SWIs) for cleaning, inspection and lubricationUse SOPs, One Point Lessons and Process Picture Maps (PPMs)Use visual aids to comm
19、unicate procedures004-7. Standardize cleaning, inspection, and lubrication procedures using Standard Operating Procedures and Standard Work Instructions (e.g., One Point Lessons, PPMs) (Step 3) Stage 2: Daily Inspections and Basic MaintenanceStep 3 Standardize cleaning, inspection and lubrication pr
20、oceduresStep 2 Eliminate contaminant sources and inaccessible areasStep 5 Operators inspect, clean, lubricate and conduct basic maintenanceEstablish Equipment Basic ConditionStep 7 Operators participate in continuous improvement activitiesDrive Continuous Improvement & QualityPerform Daily Inspectio
21、n & Basic MaintenanceStep 6 Operators are responsible for some aspects of the physical organization and management of the workplaceStep 4 Train operators to conduct daily inspection and basic maintenanceStep 1 Complete initial deep cleaningStage3Stage2Stage1Step 4: Daily Inspection and Basic Mainten
22、ance Performance ExpectationOperators should understand how the equipment functions-Basic lubrication-Machine elements (fasteners)-Pneumatics-Hydraulics-Electrical systems-Power transmission drivesTrain operators in basic maintenance004-8. Operators are trained to conduct Daily Inspection and Basic
23、Maintenance (Step 4)Step 5: Operator AccountabilityPerformance ExpectationSelect 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)004-9. Operators have accountabil
24、ity to clean, inspect and lubricate, and conduct basic maintenance on all equipment in accordance with established SOPs and SWIs (Step 5)Stage 3: Drive Continuous Improvement and QualityStep 3 Standardize cleaning, inspection and lubrication proceduresStep 2 Eliminate contaminant sources and inacces
25、sible areasStep 5 Operators inspect, clean, lubricate and conduct basic maintenanceEstablish Equipment Basic ConditionStep 7 Operators participate in continuous improvement activitiesDrive Continuous Improvement & QualityPerform Daily Inspection & Basic MaintenanceStep 6 Operators are responsible fo
26、r some aspects of the physical organization and management of the workplaceStep 4 Train operators to conduct daily inspection and basic maintenanceStep 1 Complete initial deep cleaningStage3Stage2Stage1Step 6: Operator OwnershipPerformance ExpectationTrain operatorsDevelop SWIsBudget timeConduct for
27、mal meetingsNew responsibilities-Spare Parts Management (nuts, bolts, “o” rings, etc.)-Changeover Execution and Improvement-5S and Visual Workplace-Maintain Standard Procedures-On-line Quality-Maintenance Notifications004-10. Operators take ownership of additional responsibilities relating to their
28、work areas, not limited to but including spare parts management, changeover execution and improvement, Visual Workplace, maintenance of standard procedures, on-line quality, and maintenance notifications (Step 6)Step 7: Ownership of Additional Responsibilities Performance ExpectationParticipate in C
29、ontinuous Improvement ProjectsMinor MaintenanceImprovement of Maintenance PlansEquipment Redesign/Design004-11. Operators take ownership of additional responsibilities relating to their work areas, not limited to but including participating in continuous improvement projects, minor maintenance, impr
30、ovement of maintenance plans, and equipment redesign/design (Step 7)7 Steps divided into 3 stagesComplete deep cleaningEliminate sources of contaminantsStandardize procedures Implement basic maintenance training for operators Select basic maintenance tasks to be moved to operationsEvaluate additiona
31、l operator responsibilities (QC inspections and changeovers)Incorporate operators in continuous improvement discussions to build ownershipTopic 3: ReviewTopic 4: Progress Measurement Progress MeasurementAutonomous Maintenance MetricsMonitoring ProgressPerformance Expectation AM Step Progression Chec
32、klistsNatural team completes self-assessmentWork Area Leader reviews and verifiesSite Leadership certifies004-4. Autonomous Maintenance progress should be monitored at the Focus Factory level through work area self-assessments and Autonomous Maintenance KPI tracking.Monitoring ProgressPerformance Ex
33、pectation, continued004-4. Autonomous Maintenance progress should be monitoring at the Focus Factory level through work area self-assessments and Autonomous Maintenance KPI tracking.Progress should be communicated and celebratedFocus Factory progression is recognized when 80% of work area achieves r
34、equirementsTopic 4: ReviewAutonomous 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 by Operators (%)Topic 5: Next Steps and Course Review Review FP&R Standards and GuidelinesCreate an implementation plan to address the business challenges identified-Identify Natural Work Teams-Identify Line Sponsors, Owners and Support Resources-Create Schedule for Small Group meetingsSelect area to implement AM steps
