TPM clearly identifies roles of Top management, Operators and Maintenance

Role of Top Management in TPM & Autonomous Maintenance: For Top Management pillar champions are identified to provide  leadership in terms of:

  • Setting priorities (where to start, what next?)
  • Setting expectations (work standards to be applied consistently)
  • Giving recognition (reinforce values)

Role of Operator in Autonomous Maintenance: Key Objective of Autonomous Maintenance is to create equipment competent operators & to detect and prevent forced deterioration. As operators become more closely involved in getting the very best from their machines, they move through seven steps of Autonomous maintenance:

  1. Initial cleaning: Operators will clean the machines with an objective of identifying Abnormalities
  2. Carrying out countermeasures at the source of problems: Operators are involved in taking countermeasures to eliminate repeated abnormalities and reduce cleaning time by following standards
  3. Developing and implementing cleaning and lubrication standards: Operators are trained on following standards for cleaning, lubrication and inspection
  4. General inspection routines
  5. Autonomous inspection
  6. Organization and tidiness
  7. Full autonomous maintenance

As these seven steps are taken, over an agreed and achievable timetable, operators will develop straightforward common-sense skills which enable them to play a full part in ensuring optimum availability of machines.

Autonomous Maintenance

Role of Maintenance Team in Autonomous Maintenance: Key role of Maintenance team is to support, train & guide operators in implementation of all 7 Steps of Autonomous Maintenance

  1. Refurbish critical equipment and establish back-up strategies
  2. Contain accelerated deterioration and develop countermeasures to common problems. Establish correct parameter settings.
  3. Set condition monitoring and routine servicing standards to improve response times and reduce sporadic failures.
  4. Use event analysis to fine-tune asset care delivery towards zero breakdowns.
  5. Routine restoration of normal wear to stabilize component life. Hand over routine maintenance to operators.
  6. Use senses to detect internal deterioration.
  7. To extend component life and improve equipment life prediction