Module 12
Autonomous Maintenance for Operators
Best Practices and Operational Standards for Operators
Description
Autonomous Maintenance (AM) is dedicated to Operators. It is a great idea of TPM strategy to make operators directly involved in improving machines availability and enhancing TPM overall efficiency. Since “Total” means the involvement of all and everybody in a continuous improvement and waste elimination (MUDA), the role of Maintenance evolves from reactive to preventive, and most of the daily inspections are shifted to operators.
In short, a new definition of the roles in Maintenance means that technicians and engineers focus on preventive & predictive maintenance, while production operators do the autonomous maintenance. Technicians are obliged to deal with breakdowns and restore the production, while operators are involved in eliminating micro-stoppages. Since both parties know well their machinery and equipment, the list of AM activities should arise from their common experience.
Finally, operators need to be well trained and then they can be provided with checklists to perform the tasks assigned.
This module of LEAN Academy will tell us that there are two levels of AM: level 1 – routine checks, and level 2 – specific actions e.g. lubrication, replacement of parts, cleaning etc.
Recommended Audience
Production and Maintenance management staff, Leaders, managers and LEAN specialists and wider management staff.
Methodology
Multimedia presentation, short lectures, individual exercises, group activities and discussions and Q&A
Learning Objectives
Autonomous Maintenance for Operators (1 day).
- Understanding the TPM’s concept of the division of roles in the Machinery and Equipment Maintenance.
- What the Autonomous Maintenance is and what the role of the production operators is.
- 7 standard steps to implement the AM at the production.
- AM levels and creating the checklists of the actions to be done.
- How the AM cooperates with the 5S on the operational level.
- The AM best practices for the Operators: the tools of visual management.
Tools / Templates / Methods
AM Standard Templates for the Operators
- Standard Routine Inspection, Cleaning and Lubrication Checklist. A visual template for creating the instructions for the Operators related to regular inspection, cleaning and lubrication operations.
- AM Standard Checklist for the Operators. An example of a typical checklist for confirming the execution of certain actions by the operators and production leaders.