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Autonomous Maintenance Webinar

The document summarizes an autonomous maintenance webinar. It discusses that the presentation portion will be muted for questions, questions can be asked via chat or call-in, and the recording will be available after. It then provides an overview of autonomous maintenance including restoring equipment to optimal condition through user involvement. It discusses how forced deterioration leads to failures and the need for restoration. It defines key concepts like forced deterioration and chronic vs sporadic losses. Finally, it outlines the eight steps of autonomous maintenance including initial cleaning, eliminating sources of contamination, creating inspection standards, and moving to autonomous management.

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MadhavaKrishna
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144 views37 pages

Autonomous Maintenance Webinar

The document summarizes an autonomous maintenance webinar. It discusses that the presentation portion will be muted for questions, questions can be asked via chat or call-in, and the recording will be available after. It then provides an overview of autonomous maintenance including restoring equipment to optimal condition through user involvement. It discusses how forced deterioration leads to failures and the need for restoration. It defines key concepts like forced deterioration and chronic vs sporadic losses. Finally, it outlines the eight steps of autonomous maintenance including initial cleaning, eliminating sources of contamination, creating inspection standards, and moving to autonomous management.

Uploaded by

MadhavaKrishna
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Autonomous

Maintenance
Webinar
• During presentations (12:30 – 13:00) everyone will be
muted so that only the presenter will be heard.

• The presentation will be followed by a Q&A session.


Click on the hand symbol to show that you have a
question or type your question in the question box.

• Recording will be made available after the webinar on


the Industry Forum website.

• If you are experiencing any technical problems please


call us on 0121 717 6620.
What is
Autonomous Maintenance?

A process to restore equipment to its


optimum condition

A process to involve equipment users in


the autonomous management of their
equipment
Why do we need to restore
equipment?

Research has shown that between 70% and


95% of equipment failures are due to the
forced deterioration of equipment

Restoration is the process of removing


abnormalities caused by forced deterioration
and preventing their recurrence
Why do we need autonomous
management?

Lean manufacturing require teams to respond to


customer demands as quickly and flexibly as
possible

This is only possible through autonomous


management of their processes and equipment
Key AM concepts

• Forced Deterioration

• Chronic Losses

• Sporadic Losses
What is Forced Deterioration?

Equipment deteriorates - ‘things wear’

If we don’t maintain and operate equipment


properly then it deteriorates faster – forced
deterioration
What do the effects of forced
deterioration look like?
• Contamination from product or process debris
• Minor damage - Bent Parts/Tooling, minor
cracks
• Wear and Vibration
• Leaks - air/water/steam/lubricant
• Overheating
• Missing items
• Loose fastenings
• Corrosion
Chronic and sporadic losses
A failure is the
tip of the
iceberg!
Sporadic Losses
(Breakdowns)
Failures

Wear, play, slackness,


leakage, dust, dirt, corrosion,
deformation, adherence of raw
Hidden
materials, surface damage, cracking, Expose hidden
abnormalities
which result in overheating, vibration, noise, abnormalities and
and other abnormalities prevent quality and
chronic losses
functional failures
(reduction in
before they happen
performance and
quality)
A view of equipment loss
Poorly managed equipment

Deterioration

Abnormalities
Unnoticed or
ignored

Chronic losses Sporadic losses

Lost availability,
performance and
quality
The eight steps of
Autonomous Maintenance
Step 7 – Autonomous Management
Phase 3
Step 6 - Standardisation

Step 5 – Autonomous Inspection


Phase 2
Step 4 – General Inspection

Step 3 – Create and maintain cleaning, inspection &


lubrication standards
Phase 1 Step 2 - Eliminate sources of contamination and difficult to clean and
inspect areas

Step 1 – Initial Cleaning

Step 0 – Preparation
The purpose of the phases

Phase 1 Restore equipment

Phase 2 Upskill AM teams

Phase 3 Develop Autonomous Management


Step 0 - Understand the equipment

feed funnel
air injector

Organisation
Machine / Line
Date
Created By
Issue No.
Equipment Function
Worksheet
Step 0 Worksheet 1
motor
Drawings

Notes Process for developing mechanisms


1. Identify the key mechanis ms involved in the inves tigation (follow the product flow)
2. Study and develop an understanding of function and operatios of the m echanisms
3. Draw diagrams to explain the function and operation
4. Add notes to help explain the function & s equence of operation of the m echanisms
Step 1 – Initial Cleaning
Step 2 – Eliminate Contamination
Step 2 – Eliminate Contamination
Step 2 – Ease of Inspection
Step 3 – Inspection and Lubrication
Select Model Machine
AM Team
Maintenance staff
Managers
Draft Provisional
Standards
for Cleaning
& Inspection
Trial Lubrication
AM Team
Maintenance Staff

Identify
Step 3 – Inspection and Lubrication
Provisional Standard
One Point Lesson
Check Sheet
Implementation Tips
• Choose a meaningful but manageable pilot:

• Equipment whose performance is important


but not critical

• Common equipment where lessons learned


can be duplicated

• Small enough to provide resource to follow up


on corrective actions – target 8 weeks
Implementation Tips (2)
• Choose a positive team:

• Good, stable team dynamics with good team


leader

• Previous commitment to improvement activity

• Good skill balance


Thank you for attending

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