Objectives-
- Thorough Understanding of Equipment Functions and Structure: Ensure operators have in-depth knowledge of how the equipment operates, including its functions, components, and mechanisms. This includes understanding the purpose and interplay of different parts within the equipment.
- Development of Routine Maintenance Skills with Logical Understanding: Equip operators with the skills needed to perform routine maintenance tasks on the equipment. This involves not only teaching them specific maintenance procedures but also providing the logical reasoning behind each task. Operators should understand the importance of each maintenance activity and its impact on equipment performance and longevity.
- Effective Equipment Inspection and Abnormality Identification: Train operators to conduct thorough equipment inspections to detect any abnormalities or signs of wear and tear. Operators should be able to identify even minor abnormalities precisely and accurately. This includes understanding the significance of each abnormality and its potential implications for equipment operation.
- Prompt and Effective Action for Abnormality Resolution: Empower operators to take immediate and effective action upon identifying abnormalities. This may involve addressing minor issues on the spot or escalating more significant problems to the appropriate personnel. Operators should be trained in troubleshooting techniques and equipped with the necessary tools and resources to resolve abnormalities efficiently.
AM Step 4 Process:
- Preparation:
- Finalize General & Specific Topics for Training Material Preparation: Identify the overarching themes and specific areas that need to be covered in the training material. This could include topics related to equipment performance, maintenance procedures, safety protocols, etc.
- Prepare Training Material as per Standard: Develop the training materials, which may include presentations, manuals, videos, and interactive modules, adhering to established standards and guidelines.
- Create Training Plan: Develop a comprehensive training plan outlining the schedule, objectives, delivery methods, and assessment criteria for the training sessions.
- Training:
- Train Team Leaders: Provide training sessions for team leaders to ensure they understand the material thoroughly and can effectively relay the information to their team members.
- Prepare & Provide Relay Teaching to Team Members: Team leaders should then deliver the training content to their respective team members, ensuring clarity and addressing any questions or concerns.
- Perform General Inspection, Abnormality Detection, and Correction:
- Perform General Inspection: Conduct routine inspections of the equipment to identify any abnormalities or signs of wear and tear.
- Detect & Correct Abnormalities: Upon identifying abnormalities, take appropriate corrective actions promptly to address the issues and prevent further damage or safety hazards.
- Implement Kaizens: Continuously improve the inspection process by converting variable and semi-variable checkpoints to fixed checkpoints, streamlining the inspection procedure for efficiency.
- Create List of Hard-to-Check Areas: Identify areas of the equipment that are challenging to inspect thoroughly and develop strategies to address them effectively.
- Standardization:
- Inspection Skill Evaluation & Improvement: Assess the inspection skills of operators and team leaders to identify areas for improvement. Provide additional training or support as needed to enhance their skills.
- Conduct Audits: Regularly audit the inspection process to ensure compliance with standards and identify any areas requiring further improvement or corrective action.