Total Preventative Maintenance Autonomous...
Transcript of Total Preventative Maintenance Autonomous...
Total Preventative Maintenance Autonomous Maintenance
Step 0 and 1 (Part 1) Program Initiation
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Definition: “A structured approach that establishes a corporate culture, that
will maximize production system effectiveness”.
Total – Involvement of all functions and
people at all levels of organization.
Productive – Efficient and effective utilisation
of all resources.
Maintenance – Keeping the man-machine-
material system in optimal condition.
The Aim is to prevent losses and achieve:
• Zero Accidents.
• Zero Defects.
• Zero Breakdowns.
Jishu Hozen means activities of the Production Team Member that uses
maintenance to personally conduct maintenance activities such as cleaning,
oiling, retightening and inspecting.
Jishu Hozen represents activities that eliminate equipment failures; minor stoppages; defects and losses by maintaining,
improving and restoring equipment to desirable forms.
The activities will prevent forced
deterioration of equipment, resulting in
increased production efficiency.
The Goal of Jishu Hozen is to develop operators to:
The Jishu Hozen is a step-by-step methodology for making the equipment
‘as it should be’.
Jishu Hozen has seven steps. The focus today is on Step 0 - 1, which is
‘conduct initial cleaning and inspection’.
Maintain equipment and work
places.
Follow uniformity in implementing shop floor
activities to eliminate forced deterioration on
equipment.
Become expert
equipment operators.
Jishu Hozen brings significant change to the “I Manufacture – You Repair” or
“I Make – You Fix” to “I Make – I Manage”.
Operators and Maintenance collaborate to ensure that the equipment is
completely healthy.
The Production Team Members must implement the following activities:
• Improvement of basic conditions of equipment such as Cleaning,
Lubricating, Retightening and Inspection.
• Adjustments such as adjustment in operation and setting up
prevention of quality defects.
• Prediction and early detection of abnormalities.
Forced deterioration is due to
abnormalities.
Force deterioration will occur if machines are not taken care of.
Production Team Members conduct activities to eliminate forced deterioration.
Work Together with Maintenance, eventually saving maintenance time to conduct
Planned Maintenance activities.
Grease hiding abnormalities
Recording maintenance
data to ensure feedback for prevention of recurrence.
Routine inspection on
the equipment.
Minor improvements
such as replacing parts
during abnormalities.
Speedy notification of
failures and malfunctions.
Assist in sporadic repair.
• Attention of the Team Member is diverted onto the equipment.
• 1S is Sorting the Workplace
• Tools that are kept around the equipment are classified into
necessary and unnecessary items. The sorting activity has to be
done by operators under the guidance of Supervisors or
Management.
• Decision Matrix for Sorting out Tools.
Priority
Frequency of
Use? How to Use?
Low Less than once
per Year.
Throw away.
Store away from
the workplace.
Average At least Once
per Month
Store together
but Off-line.
High Once per Day. Locate at the
Workplace.
Before and After Clearing area
The fundamental principle is
“Everything has place and everything in its place”
2S is Organising the Workplace
• Assign each Item with a label.
• Decide the right place for each necessary item, ensuring easy accessibility.
• Mark the locations.
• Draw a boundary around the
equipment/items to indicate its zone.
• Exhibit the status clearly e.g. “Tool Change”.
The Advantages of 1S and 2S are:
• Clean and efficient work place will be
created and shop floor housekeeping will
be of highest order.
• Movement of Team Member will be
minimized.
• Time spent searching for necessary items
are eliminated.
• Safer working conditions ensured.
• Increased productivity.
Form a cross-functional team comprising of shift operators, maintenance staff, office
staff and supervisors. All Team members need to know the meaning of
“Abnormalities”.
Initial cleaning materials required before commencing
with Step 1:
• White and Red tags, brushes, rags, cleaning
solvent, gloves, torchlight, cable ties and tool box.
All Team Members briefed on the Safety aspects of
equipment before cleaning.
Video and photographs captured before and after
initial cleaning. Management and workforce working together as a team, showing commitment to program
Audits are carried out to ensure the achievement of success of each step. Audits are carried out
in three stages by the:
• Team who had carried out the activity.
• Manager of the area.
• Unit head along with the TPM Secretariat.
The equipment should get at least 80 points during the Unit head audit. Thereafter, the next step
may commence.
The benefit is the operator is carrying out the
Important tasks and finding issues with the aim of
Bringing the equipment to “As New”