Total Preventative Maintenance Autonomous Maintenance

Step 0 and 1 (Part 2) Program Initiation

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Cleaning and inspection marks the crucial start of the Jishu Hozen activities.

Cleaning helps to find what is wrong with the equipment.

The three main points to remember about cleaning and inspecting are:

Cleaning is inspection.

Inspection means finding problems.

Problems leads to either restoration or improvement.

Gemba walks and Layered Audits are vitally important. The purpose of these management tools are to ensure compliance. Failure from management to do these activities will result in 1 & 2 S system failures. Visuals to be close to machinery or on display boards purpose built for the area Summary objective of Step 0 • Assisting workers to understand how equipment deterioration occurs • Understanding safety critical actions • Ease in identifying abnormal conditions

Inadequate cleaning is often the cause of equipment malfunctioning and quality problems.

Examples are:

• Dirt on clutches and work pieces in automated equipment can affect the workflow, cause

malfunctions and minor stoppages.

• In electroplating, contaminated work pieces or dirt in the electrolyte can cause plating

defects.

• In Paint shops contamination from one department can find its way to another

Before abnormalities are hidden by a machine covered in grit and grime

After abnormalities are uncovered and the machine can be properly maintained

• Tools to convey information regarding equipment knowledge and skills, regarding trouble or improvement cases.

• Designed to help enhance knowledge and skills in a short period of time.

• To upgrade the level of expertise of the whole team.

One Point Lessons are:

One Point Lessons act as learning`s for others in the organization.

• The basic principle is for individual

members to personally think, study

and prepare a sheet with originality.

• Explain its content to team members.

• Thereafter, conducting free

discussions on the spot to make the

issue clearer and unquestionable.

Details for documentation control.

Prepared by, the date and the theme heading

Hand drawn explanation of what and how to grease nipple

Hand drawn explanation how to use the grease gun

Tagging is the visual representation of abnormalities in equipment. The tagging

speeds up the removal of abnormalities.

White Tags- If the operators are able to correct abnormalities

themselves then a white tag is located at the

abnormality.

Red Tags- Where red tags are located at abnormalities, the

maintenance personnel are

required to action.

Once the abnormalities are

rectified, the relevant tags will be removed.

Equipment Name..................................................

Control Number:....................................................

Date of Detection:..................................................

Detected by:............................................................

Description of Minor Defects:...............................

..................................................................................

..................................................................................

Total Productive Maintenance

White Tags

Equipment Name..................................................

Control Number:....................................................

Date of Detection:..................................................

Detected by:............................................................

Description of Minor Defects:...............................

..................................................................................

..................................................................................

Total Productive Maintenance

Red Tags

White Tags

• White Tags show Issues that the Team Member can

sort out themselves.

• Red Tags require expert maintenance support

• All this information is captured in a tag register to

ensure closing of issues and traceability

Red Tags

Shows information such as

• Equipment Name

• Control Number

• Date Detected

• Detected by

• Description of defect

1. Minor Flaws

2. Unfulfilled basic conditions

3. Inaccessible places

4. Contamination sources

5. Quality defect sources

6. Unnecessary and non urgent items

7. Unsafe places

Minor Flaws.

Contamination. Dust, dirt, powder, oil, grease, rust, paint.

Damage. Cracking, crushing, deformation, chipping, bending.

Play. Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion.

Slackness. Belts, chains.

Abnormal Phenomenon. Unusual noise, overheating, vibration, strange smells, discoloration,

incorrect pressure.

Adhesion. Blocking, hardening, accumulation of debris, peeling, malfunction.

Unfulfilled Basic

Conditions.

Lubrication. Insufficient, dirty, 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 backwards.

• Aim and benefit of One Point Lessons and tagging of abnormalities

is to prevent forced machine breakdown

• Forced machine breakdown is caused by the listed abnormalities

Inaccessible Places.

Cleaning. Machine construction, covers , layout, footholds, space.

Checking. Construction, covers, layouts , footholds, instrument position and

orientation, operating range display.

Lubricating. Position of lubricant inlet, construction, height, footholds, lubricant

outlets.

Tightening. Covers, construction, layout size, space.

Operation. Machine layout, position of valves, switches and leavers,

footholds.

Adjustments. Position of pressure gauges, thermometers, flow meters, moisture

gauges, vacuum gauges.

Contamination

Sources.

Product. Leaks, Spills, Spurts, Scattering, Overflow.

Raw Materials. Leaks, Spills, Spurts, Scattering, Overflow.

Lubricants. 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 materials and non conforming

product.

Others. Contaminants by people and forklifts, infiltration through cracked

walls, broken windows.

• Aim and benefit of One Point Lessons and tagging of abnormalities

is to prevent forced machine breakdown

• Forced machine breakdown is caused by the listed abnormalities

Quality Defect Sources.

Foreign Matter. Dust, rust, powder, chips, moisture, wire, scraps, wood pieces,

paper pieces, stones.

Shock. Dropping, Jolting, collision, vibration.

Moisture. Too little of too much infiltration.

Gain Size. Abnormalities in screens, compressed air separators, centrifugal

separators.

Concentration. Inadequate warming, heating, compounding, mixing, evaporation,

stirring.

Viscosity. Inadequate warming, heating, compounding, mixing, evaporation,

stirring.

Unnecessary and Non-

Urgent Items.

Machinery. Pumps, fans, compressors, columns, tanks.

Piping Equipment. Pipes, hoses, ducts, valves, dampers.

Measuring Instruments. Temperatures, pressure gauges, vacuum gauges, ammeters.

Electrical Equipment. Wiring, piping, power leads, switches, plugs.

Jigs and Tools. General tools, cutting tools, jigs, dies, frames.

Spare parts. Standby equipment, spares, permanent stock, auxiliary materials.

Makeshift Repairs. Tape, string, wire, metal plates.

• Aim and benefit of One Point Lessons and tagging of abnormalities

is to prevent forced machine breakdown

• Forced machine breakdown is caused by the listed abnormalities

Unsafe Places.

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

chucker plates, slipping.

Steps. Too steep, irregular, slipping, missing handrails.

Lights Dim, out of position, dirty and broken covers, no explosion proofing.

Rotating Machinery. Displaced, fallen oil or broken covers, not safe for emergency,

missing emergency stop devices.

Lifting Devices. Wires, hooks, brakes and other parts of cranes and hoists.

Others. Special substances, solvents, toxic gases, insulating materials,

danger signs, protective clothing.

Hindsight Engineering; if only we had…..

Clean and inspect the

selected equipment – make use of the 5 senses

and record the cleaning time.

Determine the abnormalities – make use of the 7 types of Abnormalities.

Locate tags on abnormalities.

Prepare a list of unfilled

basic conditions.

Compile a list of hard to

clean, lubricate, tighten,

inspect and adjust.

Carry out an audit on the

1st Step.

Carry out a meeting after

the daily activities.

Directional flow indicators Operational range

Revision 1 2014/01/14

TPM Training Schedule

Participants: AIDC Team, Senior Management Team, Production Team.

Aim: To present the fundamentals of Autonomous Maintenance and start

company’s journey through Total Productive Maintenance.

Training Schedule:

Step 0 theory 30 Minutes

Step 0 practical training 1 Hour

Step 1 theory 1 Hour

Step 1 practical training 1.5 Hours

Step 1 closing and findings discussion 30 Minutes

Followed up with daily cleaning and weekly meetings