Autonomous Maintenance : Definition

SHARED RESPONSIBILITY OF MAINTAINING ”BASIC CONDITIONS” OF EQUIPMENT

BETWEEN PRODUCTION AND MAINTENANCE

 Daily/Time-Based Maintenance
– Cleaning
– Lubrication
– Tightening

 Daily inspection by using 5 SENSES

 Right operation, right adjustment, right setting

“I operate, You fix.” “We are AlI responsible for

Our equipment.”

“I operate, You Clean.” “We are AlI responsible for

cleanliness of Our line.”
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3 Key Tools for Autonomous Maintenance
Key Concepts
3 Key Tools
• Shop floor based activities
• Operator conducted  Activity Board
• Operator enhancing
• Team activity
• Autonomous Management  Meetings
• TPM Foundation
• Part of the job!
 One Point Lessons

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 Example of A.M. Activity Board
Activity & Findings Treasures
People
Team Team Mission •Display actual findings from
Step 1: Initial Cleaning Initial Cleaning such as trash,
•Team Name •Mission unnecessary items, dust and
•Members •Objectives Definition other contamination.

Step 2: Sources of Contamination

Pictures Before After

Explain and show Focused

Line Improvement activities
for sources of contamination
Layout of Line &
Identified Important
Areas
Tag List Production Maintenance
Safety Hazard One-Point-Lessons

Contamination
Tag Movement
Hard-to-reach
Actual Tags
Main Failure

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One Point Lessons TPM One-Point Lesson
One Point Lesson is a tool
No. DL1034
with the following

Subject
Compressed Air Usage
For Line #1 & 2 Date of
characteristics; Creation
November, 2003

Dept. Super- Team Created

Classification
Manager visor Leader by

 One sheet Basic Im provem ent Trouble

John Jerry Paul Daniel

 to share the results Knowledge Example Cases

1.Compressed Air
of autonomous study 1 may only be used on
 for 5-10 minutes the Dribbler Scale
ONLY

2.Scale Area is
currently Hard-To-
Contents can be knowledge Reach and may
and skills of; cause variable
2
 Equipment weight if not
cleaned
 Safety Don’t Make A Bigger Mess !!!

 Operation Process Date

Action History
Executed
 Task Instructor

Trainee

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The 7 steps of Autonomous Maintenance
1. Initial Cleaning -Detect problems of lines and restore its original state.
(Initial Inspection & -Start managing the line autonomously.
“Restoration”) ( 5S, Minor Stops, Quality )
-Create & perform temporary
“Cleaning/Lubrication procedures.”

2. Source of Contamination -Solve “Sources of Contamination” and

& Hard-to-Reach areas “Hard to Reach” areas. (Cleaning, Inspection, Lubrication)
3 Years

3. Standards of Cleaning -Develop tentative standards for cleaning, lubrication and

& Lubrication inspection.

-Provide training on their equipments, products and

4. General Inspection materials, inspection skills and other AM skills.

5. Autonomous Inspection Develop a routine maintenance standard by operators

6. Standardize Autonomous Standardize routine operations related to workplace

Maintenance operations management such as quality inspection of products,
life cycle of jigs, tools, set up operation and safety.
7. Autonomous Autonomous team working
Management

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 JISHU- HOZEN
STEP - 0 Initial Preparation

. Prep of JH Activities

1. Prep a Cleaning & Lubrication Map

2. Arrange Tools

3. Arrange Red & White Tags

4. History of Failures

5. Training on 7 Steps of Jishu Hozen

6. Gant Chart

7. Training on 7 Types of abnormalities

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What to detect during Initial Cleaning?
“Categories of Abnormality”
S: Safety Items : safety area, spot, work environment
1: 5 S Related Items:
 Sort: Unnecessary items
 Store: Disorganized storage, Lack of Visual Indications
 Shine: Cleanliness/Preserve
2: Sources of Contamination:
 Leaks, Spills
3: Hard-to-Reach area
4: Broken/Missing Parts
5: “Basic Conditions”:
 Lubrication
 Tightening
 Cleaning & Inspection
6: Quality Related: Causes of defect

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 JISHU- HOZEN
STEP - 1 Initial Cleaning

1. Cleaning is Inspection 5. Make the List of

2. Use 5 Senses for Cleaning Hard to Clean

Hard to Lubricate
3. Find out 7 Types of Abnormalities Hard to Tighten
Hard to Inspect
4. Put Tags on Abnormalities
Hard to Adjust

Record cleaning time

Carryout Audit on 1st Step
Meeting after the Daily Activities
Refers to the Old History Records

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 F-Tagging
During Afterwards –
Initial Cleaning Every Day Process

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Monitoring Tags
• Initial Cleaning is not an one time event. It should be repeated monthly.
• The more restoration you continue, the less Initial Cleaning time you will need.
250

Tag Issued
200

Tag
Number of Tags

150
Restored

100

50

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 JISHU- HOZEN
STEP - 1 Initial Cleaning – 7 Types of Abnormalities

2. Sources 1. Minor Flaws

Contamination
Quality Defect

2. Places 1. Unfulfilled Basic Conditions

In Accessible
Unsafe

1. Items

Un-necessary – Non Urgent 37

 JISHU- HOZEN
STEP - 1 Initial Cleaning – 7 Types of Abnormalities

1.Minor Flaws

Contamination Dust, Dirt, Powder, Oil, Grease , Rust, Paint

Damage Bending, Cracking, Crushing, Chipping, Deformation

Play Shaking, Falling Out, Tilting, Eccentricity, Wear, Distortion,
Corrosion

Slackness Belts, Chains

Abnormal Unusual Noise, Overheating, Vibration, Strange Smells,

Phenomenon Discoloration, Incorrect Pressure or Current

Adhesion Blocking, Hardening, Accumulation of Debris, Peeling,

Malfunction 38
 JISHU- HOZEN
STEP - 1 Initial Cleaning – 7 Types of Abnormalities

2.Unfulfilled Basic Conditions

Lubrication Dirty, Insufficient, Unidentified, Unsuitable, Leaking

Lubrication Supply Dirty, Damaged or deformed lubricant inlets, faulty

lubricant pipes
Oil Level Gauges Dirty, Damaged, Leaking, No indication of correct level.

Tightening Nuts and Bolts slackness, Missing, Cross-Threaded,

Too long, Crushed, Corroded,
Unsuitable washers, wing nuts on backward

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 JISHU- HOZEN
STEP - 1 Initial Cleaning – 7 Types of Abnormalities

3. Inaccessible Places

Machine Construction, Covers, Layout, Footholds, Space

Construction, Covers, Layout, Footholds, Instrument

position and Orientation, Operating – Range Display
Position of Lubricant Inlet, Construction, Height, Footholds,
Lubricant outlet, Space
Covers, Construction, Layout size, Space
Machine Layout, Position of Valves, Switches and Leavers,
Footholds

Position of Pressure Gauge, Thermometers, Flow

Meters, Moisture Gauges, Vacuum Gauges etc. 40
 JISHU- HOZEN
STEP - 1 Initial Cleaning – 7 Types of Abnormalities

4. Unsafe Places

Floors Unevenness, cracked, holes, projections, peeling, wear of

steel chucker plates, slipping.

Steps Too steep, irregular, slipping, missing Hand rails

Lights Dim, out of Position, dirty / broken covers,, no explosion
proofing etc
Rotating Machinery Displaced, Fallen oil / broken covers, not safe for
emergency, Missing emergency stop Devices

Lifting Devices Wires, Hooks, Brakes & Other parts of cranes and Hoists
Others Special Substances, solvents, Toxic gases, Insulating
materials, danger signs, protective clothing etc. 41
 JISHU- HOZEN
STEP - 1 Initial Cleaning – 7 Types of Abnormalities

5. Contamination Sources

Product Leaks, Spills, Spurts, Scattering, Overflow

Raw Materials Leaks, Spills, Spurts, Scattering, Overflow

Lubricants Leaking, Spills, Seeping Oils, Hydraulic Fluids, Fuel Oils

Gases Leaking compressed air/gases/steam/vapors/exhaust fumes

Liquids Leaking Water/hot/cold, Half Finished Products, waste Water,

Leaking Supply lines
Scrap Flashes, Cuttings, Packaging material and NC Products
Others Contamination by people & Forklifts, Infiltration through
cracked walls, broken windows etc. 42
 JISHU- HOZEN
STEP - 1 Initial Cleaning – 7 Types of Abnormalities

6. Quality Defect Sources

Foreign Matter Dust, Rust, Powder, chips, Moisture, Wire scraps, Wood
Pieces, Paper pieces, stones etc.
Shock Dropping, Jolting, Collision, Vibration etc.
Moisture Too little or Too Much, Infiltration

Gain Size Abnormalities in Screens, Compressed air separators,

Centrifugal Separators
Concentration Inadequate Warming, Heating, Compounding, Mixing,
Evaporating, Stirring etc.

Viscosity Inadequate Warming, Heating, Compounding, Mixing,

Evaporating, Stirring etc. 43
 JISHU- HOZEN
STEP - 1 Initial Cleaning – 7 Types of Abnormalities

7. Un-Necessary and Non Urgent Items

Machinery Pumps, Fans, Compressors, Columns, Tanksers

Piping Equipment Pipes, Hoses, Ducts, Valves, Dampers etc.

Measuring Temperatures, Pressure Gauges, Vacuum Gauges, Ammeters

Instruments etc
Electrical eqpt Wiring, Piping, power leads, Switches, Plugs etc.

Jigs & Tools Gen Tools, Cutting Tools, Jigs, Molds, Dies, Frames etc.
Spare Parts Standby eqpt, spares, permanent stocks, Auxiliary material

Makeshift Repairs Tape, String, Wire, Metal plates etc.

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 Before After

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Major Impact from Initial Cleaning Activity
• 10 % increase in Machine Time by cleaning and adjustment of cylinders and air tubes of
Bag Former
(13 cycle/min to 15 cycle/min)

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