Autonomous Maintenance Steps: Step 0

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LEAN | TPM | Autonomous Maintenance Steps | Step 0: Education

You may know the Autonomous Maintenance steps, but did you know there is a step 0 before Autonomous Maintenance Step 1? This article explains and has a free Autonomous Maintenance PDF to help you share Step 0 with others.

With the growing demand for manufacturing facilities, authorities took many actions to escalate the efficiency of production processes. Many formal methods were implemented for a longer period of time without acquiring significant growth in the field. But with the introduction of Autonomous Maintenance (AM) to modern manufacturing facilities, they achieved an increment in efficiency and productivity at a historical brisk pace.

Total Productive Maintenance (TPM) was initially practiced in a subsidiary company related to Toyota and it concerns about improving the Overall Equipment Effectiveness (OEE) of machinery used in the production facility. lean and TPM are commonly addressed when it comes to modern manufacturing facilities while TPM within lean tries to increment the productivity of a facility, ultimately LEAN philosophy targets to reduce waste. Autonomous maintenance is listed first in the 8 pillars of TPM and it’s considered a key concept of total productive maintenance.

Most of the machines used in modern facilities are a result of sophisticated technology and technicians with a versed knowledge are responsible for the health of such machines. When compared to technicians, machine operators spend a considerable amount of time with the machine throughout their working hours. With the repetitive actions performed in the same machine for a prolonged period of time, machine operators gain experience with the working patterns of the machine. Those experiences can be used to perform small kinds of maintenance actions on the machine. Hence dedicated technicians are no longer needed to perform such maintenance activities as General Visual Inspection (GVI), lubrication, bolt tightening, monitoring, and cleaning.

Autonomous Maintenance Step 0:

Autonomous maintenance is achieved by undergoing 7 simple steps and the initial step being, Step 0: Operator Autonomous Training. In step zero of autonomous maintenance, the goal is to increase basic understanding of machine components and train machine operators to perform maintenance activities to a certain level. If the maintenance action is too complex for a machine operator, technicians can be called upon for assistance. With the relief from ordinary maintenance activities technicians can be detailed for specific improvement and preventative tasks that require technical expertise. Autonomous maintenance directly impacts the Overall Equipment Effectiveness and OEE can be raised by adopting autonomous maintenance actions which are outlined under autonomous maintenance as described above.

Approved training is mandatory to train machine operators to perform such maintenance tasks to achieve planned effectiveness and to reduce accidents that may encounter during newly incumbent tasks. A proper training program can standardize the tasks and assist machine operators to comply with the correct standards. Technical experts within the company are good assets that can be utilized to conduct training programs for the operators. Machine one point lessons, instructional videos, and machine component sheets can be utilized to enhance the effectiveness of the training program.

Nowadays courses which are offered through the internet has become the prime concern in training due to their high quality and availability. Most of such courses contain instructional videos to make the learning experience more interesting and effective.

Being trained under Step 0: Operator Autonomous Training, operators can proceed a step forward by commencing some autonomous maintenance activities. The actions to be performed next is explicitly stated in the Autonomous Maintenance Step 1: Thoroughly clean equipment and its surroundings. When the machine operator arrived at the Autonomous Maintenance Step one, they are equipped with the necessary information which was taught in step zero to perform needed maintenance tasks. Hence going through step zero is mandatory before step one to ensure the safety of the machine operator and integrity of the task performed.

Already started your Autonomous Maintenance Program? Remember AM Step 6: Continuous Improvement and AM Step 7: Continuous Education! So don't let having an existing Autonomous Maintenance program in place stop you from educating your operators more about the equipment and maintenance practices.

References:

1) https://bin95.com/vocational-training/maintenance/reliability-training.htm

2) https://bin95.com/AM-Steps-0-1.pdf(This AM Steps article in PDF format)

3) https://www.slideshare.net/bin95/lean-tpm-autonomous-maintenance-2

4) https://www.industryforum.co.uk/resources/articles/autonomous-maintenance/

5) https://leanmanufacturingtools.org/438/autonomous-maintenance/

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TOPICS: LEAN TPM |tpm maintenance | autonomous maintenance | autonomous maintenance step 1 LEAN TPM tools and resources referenced in this autonomous maintenance are are OEE, 5s, and our in-house operator training program.

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