HOW PREPARE THE 4 STEP IN AUTONOMUS

MAINTENANCE- TPM PILLAR -

Three schematic routes for its construction and execution

The successfully sinergy between pillars Planned Maintenance, Education and Training for this

construction and execution

PRIORITIZING PROBLEMS(Mode-Fault-Component Matrix,Map of abnormalities y criticality

of equipment)Pillars Manteniance and Training

BUILD SUPPORT MATERIALFOR EACH TOPIC

(Documents, prototypes, etc.)

PLANNING MANTENIANCEDEFINES TRAINING TARGETS

GOALS TO OBTEIN AT END OF STEP:- Failures decreases by 90%- Quality defects decreases by 50% (QA matrix) {a}- Quality claims decreases by 20% to 30% {a}- Zero Accidents- Increased abnormalities card generation (Red and blue)- Elimination of dirt and local sources dif f icult to access -> Continuosimprovement cycle- Standars upgrade -> Continuos improvement cycle

CRITERIA FOR SELECTING OPERATIONS TO TRANSFER TOOPERATORS:

- They are covered in the training- No special tools required- No need additional safety skills- Not required major equipment disarmsConsider w hether additional know ledge is needed outside of training, toprogram according to curriculum development

PM, but with leading and supporting byTraining in pedagogical cri teria

BASIC SCHEMA FOR ACTIVITIES FOR 4 AM'S STEP

PILLARS OF SAFETY, QUALITY..., REVIEW SUPPORT

MATERIALS THATINSTRUCTORS WILL USE IN

TRAININGS

EVERYTHINGSRIGHT?

SET ACCORDING TOCOMMENTS A

SUGGESTIONS

No

PILOT TRAINING BEFOREMAKING DIRECT TO

COORDINATORS AND/ORTEAM LEADERS (Validation of

training method)

EVERYTHINGSRIGHT?

No

Yes

Yes

CYCLE TRAINING PROCESS EXECUTION, MONITORINGAND AUDIT A OPERATION IN EACH SUBJECT

Theoretical and practical training

Monitoring knowledge and skills taught (in theworkplace and through the Four Steps Method)

Internal audits: Workgroup and his coordinators(team leaders)

Pillars Audit coordinators and workgroup

EVERYTHINGSRIGHT?

No

Yes

SET ACCORDING TOCOMMENTS A

SUGGESTIONS

CONTINUE TONEXT LEVEL

AUDIT FINAL STEP

KEY DELIVERABLES IN EACH SUBJECT:- Abnormalities identif ied and managed by team members

- Sources of pollution and Hard to Reach Places eliminated.- Updated Standards

- OLP assigned- Hidden risks identif ied and controlled

- Others as the subject and the need of the area

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{a} Only suggest values. It's necessary checkthe historic quality data at begining step, forset goals to real situation in line or area.

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DEFINITION ANDPRIORITIZING OF

SUBJECTS

Definition of subjects

List of interventions to transfer from PM to AM

Complete?

No

CONSTRUCTION/REVISION OF

TRAINING MATERIALYes

Revision of material and available documents

Prototypes, Models

OPL

Videos

Handbooks, books

Instructor´s plan

Basic analysis, CAP-Do, etc.

Powerpoint presentations(OPTIONAL)

Complete?

No

YesEXECUTE PILOTS OF

EACH SUBJECT

PRESENTATION OFTRAINING PLAN

Yes

Cronogram

List of interventions to transfer

General Plan of training in workplace (OJT)

Complete?

No

YesEXECUTION OF

PLAN

GUIDE TO PREPARING AND CHECKINGTRAINING IN 4 STEP IN AM'S

Area/Line coordinators,team leaders

This activity can be after presentation of thetraining plan:

Pillars (Led by Training pillar), area or linecoordinators, plant manager...

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THIS METHOD IS TEACHED BY TRAINING PILLAR THROUGH SOME EXERCISES THATENSURE IN INSTRUCTORS ITS KNOWLEDGE AND APLICATION WHEN THEY ARETEACHING OTHERS.FOR THE PLANS CONSTRUCTION, THE TRAINING PILLAR TEACHS ABOUT ITSCONSTRUCTION, AND BESIDES REVIEW THEM INCLUDING THE OLP, STANDARDSAND OTHER DOCUMENTS THAT WILL BE USED IN THE TRAINING MOMENTS WITHLEARNERS.

APPLY THE TRAININGUSING THE "FOUR STEPS

METHOD" (OJT)

SUPPORTING ANDCORRECTING IN THE

WORKPLACE

EVERYTHING AREACCORDING WITH

CONDITIONS?

LAST MONITORING INWORKPLACE

CERTIFICATE THE NEWSKILL

UPGRADE THECOMPETENCES/SKILLS

MATRIX

Yes

NO

PROCEDURE TO TRAINING IN COMPETENCES AND SKILLS

PLANNING ABOUT POINTOR ACTIVITY TO TRAIN

"FOUR STEPS METHOD TO TRAINING" (OJT METHOD):1. DIAGNOSE / MOTIVATE AND THEN SHOW : INSTRUCTOR QUESTIONS , INQUIRES AND

MOTIVATES THE LEARNER ABOUT NEW KNOWLEDGE AND SKILLS. DEMONSTRATE AND

EXPLAIN DONE SIMULTANEOUSLY . THE LEARNER PAY ATTENTION .2. TRY: THE INSTRUSTOR ASKS THE LEARNER TO EXPLAIN AND HE DOES AS

INSTRUCTED .3. TEST: HERE THE LEARNER EXPLAINS AND DOING THE PROCEDURE FOLLOWING

SECURITY NORMS TO AVOID FAILURES , ACCIDENTS AND QUALITY PROBLEMS .4. MONITORING . THE INSTRUCTOR AND LEARNER AGREE ABOUT DOING SOME

EXERCISES SIMILAR TO 4 STEP OF THIS METHOD , UNTIL THE KNOWLEDGE AND SKILL

ARE FIXED IN THE OPERATOR . THIS STEP ENSURES THAT THE SKILL IS ACQUIRED .

ATTENTION: IN EVERY MOMENT , THE INSTRUCTOR CORRECTED WHEN NECESSARY .

POINTS TO CONSIDER IN THESE PLANS:WHAT TOOLS ARE NECESSARY ?OLP AND/OR STANDARS CAN USE DURING THE TRAINING .ARE NECESSARY SOME SECURITY PERMISSIONS ?ARE THERE HEALTH RESTRICTIONS ?HOW LONG WOULD TAKE THE TRAINING ?

THE NEW ACTIVITIESLEARNED NOW ARE

RESPONSABILITY OFOPERATORS (AM)

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