Objectives-
- Minimize Sources of Contamination & Cleaning Time:
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- Conduct a thorough assessment of the facility to identify potential sources of contamination.
- Implement measures such as sealing openings, improving air filtration systems, and controlling access points to minimize contamination.
- Streamline cleaning procedures by identifying and eliminating unnecessary steps, optimizing cleaning schedules, and investing in more efficient cleaning equipment.
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- Prevent Dirt/Dust Outbreaks:
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- Implement regular maintenance schedules for equipment and facilities to prevent the build-up of dirt and dust.
- Train employees on proper housekeeping practices and provide tools and equipment for regular cleaning.
- Consider implementing measures such as air curtains, dust collectors, and positive pressure systems in critical areas to minimize dirt and dust accumulation.
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- Identify and Plug Sources of Dirt/Dust/Leaks/Spills:
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- Conduct regular inspections to identify potential sources of dirt, dust, leaks, and spills.
- Implement preventive maintenance programs to address issues before they escalate.
- Invest in leak detection systems and implement containment measures for hazardous materials.
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- Localize Dirt/Dust/Leak/Spill:
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- Implement zoning and labelling systems to clearly identify different areas of the facility and the types of activities conducted in each zone.
- Train employees on proper waste management and spill response procedures.
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- Eliminate Hard to Access Areas:
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- Assess the layout of the facility to identify hard-to-access areas.
- Consider redesigning the layout or implementing modular equipment to improve accessibility for cleaning and maintenance.
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- Reduce Inspection Time:
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- Implement predictive maintenance strategies using sensors and monitoring systems to identify potential issues before they occur.
- Train maintenance staff on efficient inspection techniques and prioritize inspections based on risk assessment.
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- Make Visual Workplace:
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- Utilize signboards, outlining, color coding, and direction/level indicators to clearly communicate safety procedures, equipment locations, and workflow directions.
- Implement transparent guards and footprints to guide employees and visitors safely through the facility.
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- Reduce Lubrication Time:
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- Standardize lubrication procedures and schedules to optimize efficiency.
- Implement centralized lubrication systems where applicable to reduce manual lubrication time.
- Train maintenance staff on proper lubrication techniques and use visual aids to identify lubrication points.
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AM Step 2 Process:
- Create Machine Map:
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- Begin by creating a detailed map or layout of the machines or equipment involved in the process. This map should include all components, subsystems, and critical areas relevant to the process.
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- RCA (Root Cause Analysis) / Why Why Analysis:
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- Perform a root cause analysis or a “Why Why” analysis to identify the underlying causes of issues such as downtime, contamination, or inefficiencies in the process.
- Ask “why” multiple times to drill down to the root cause of the problem.
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- Countermeasures:
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- Based on the findings of the RCA/Why Why analysis, develop and implement countermeasures to address the identified root causes.
- Countermeasures could include procedural changes, equipment modifications, training programs, or other interventions aimed at preventing recurrence of the identified issues.
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- Results of Countermeasures: Reduced CLIT Time:
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- Measure the effectiveness of the implemented countermeasures by tracking key performance indicators (KPIs) such as CLIT (Cleaning, Lubrication, Inspection, and Tightening) time.
- Analyze the data to determine if the implemented countermeasures have resulted in the desired improvements, such as reduced CLIT time.
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