TPM Autonomous Maintenance

Planned Maintenance teams in TPM Program generally consists of team members from maintenance team where is Autonomous maintenance team have more of production team members as objective of autonomous maintenance is to create equipment competent operator. however to train operators to identify & correct abnormalities on their machines, Planned maintenance teams should support them. Following are roles of Planned Maintenance teams in Autonomous Maintenance steps

Autonomous Maintenance Step 1:

  • To explain machine function and mechanical functions and define basic conditions – normal and abnormal
  • Guidance for Identification of cleaning, inspection and lubrication items and Cleaning tools management
  • Abnormality identification training – and teach about red/white tags
  • Teach how to develop One Point lessons
  • Help to dis-cover difficult to access areas
  • Inspection while cleaning –teaching this to operators.
  • Training the operators on moving parts, functional inspection of the rotating mechanisms, to find out abnormalities and making operators judge pass-fail criteria.

Autonomous Maintenance Step 2:

  • Assist and implement countermeasures for sources of contamination by fabricating
  • carrying out trials, installing and improving guards etc. This will include activities such as:
  • Make machine easy to clean, lubricate and tighten – by operator with their involvement.
  • Conducting WHY-WHY analysis of breakdown and if the reason being lack of Autonomous Maintenance activities then fill the skill gap.
  • Prepare localized guards & Arrest leakages
  • Removal of red/pink tags – explain and do.
  • Rectifying the major abnormalities, which cannot be done by operators.
  • To train the operators for developing, with one point lessons.
  • To train operators to conduct daily autonomous maintenance activities safely.
  • Attend to suggestions made by operators in form of countermeasures by AM team that they couldn’t implement themselves.

Autonomous Maintenance Step 3:

  • Preparation of visual control – to make the changes in equipment including auxiliary units so that they are easy to clean, access, inspect and lubricate.(Re-tighten) make the equipment ‘visually controllable’ by operators
  • Decide frequency for Cleaning, lubricating, tightening, making the method to do it and decide who will do what. Then teach that person ‘How’ to do.
  • Provide the right kind of tools near the machine for operator to use. Similarly provide appropriate tools to maintenance for their work
  • Prepare Breakdown sheet on which all breakdowns will be recorded and analysed
  • Correct abnormalities that are identified through inspection.
  • Establish standards for lubrication and monitoring pressure/temperatures
  • Establish standards for cleaning