Total Preventative Maintenance Autonomous Maintenance

Transcription

1 Total Preventative Maintenance Autonomous Maintenance Step 0 and 1 (Part 2) Program Initiation Autonomous Maintenance Focussed Improvement Effective Maintenance Education and Training Early Management Quality Maintenance TPM in Administration Safety, Health, Environmental 5 S

2 Cleaning and inspection marks the crucial start of the Jishu Hozen activities. Cleaning helps to find what is wrong with the equipment. The three main points to remember about cleaning and inspecting are: Cleaning is inspection. Inspection means finding problems. Problems leads to either restoration or improvement.

3 Gemba walks and Layered Audits are vitally important. The purpose of these management tools are to ensure compliance. Failure from management to do these activities will result in 1 & 2 S system failures. Visuals to be close to machinery or on display boards purpose built for the area Summary objective of Step 0 Assisting workers to understand how equipment deterioration occurs Understanding safety critical actions Ease in identifying abnormal conditions

4 Inadequate cleaning is often the cause of equipment malfunctioning and quality problems. Examples are: Dirt on clutches and work pieces in automated equipment can affect the workflow, cause malfunctions and minor stoppages. In electroplating, contaminated work pieces or dirt in the electrolyte can cause plating defects. In Paint shops contamination from one department can find its way to another

5 Before abnormalities are hidden by a machine covered in grit and grime After abnormalities are uncovered and the machine can be properly maintained

6 One Point Lessons act as learning`s for others in the organization. Tools to convey information regarding equipment knowledge and skills, regarding trouble or improvement cases. Designed to help enhance knowledge and skills in a short period of time. To upgrade the level of expertise of the whole team. One Point Lessons are: The basic principle is for individual members to personally think, study and prepare a sheet with originality. Explain its content to team members. Thereafter, conducting free discussions on the spot to make the issue clearer and unquestionable.

7 Details for documentation control. Prepared by, the date and the theme heading Hand drawn explanation of what and how to grease nipple Hand drawn explanation how to use the grease gun

8 Tagging is the visual representation of abnormalities in equipment. The tagging speeds up the removal of abnormalities. White Tags- If the operators are able to correct abnormalities themselves then a white tag is located at the abnormality. Once the abnormalities are rectified, the relevant tags will be removed. Red Tags- Where red tags are located at abnormalities, the maintenance personnel are required to action.

9 White Tags show Issues that the Team Member can Total Productive Maintenance White Tags Equipment Name... Control Number:... Date of Detection:... Detected by:... sort out themselves. Red Tags require expert maintenance support All this information is captured in a tag register to ensure closing of issues and traceability Description of Minor Defects: Total Productive Maintenance... Red Tags Equipment Name... White Tags Control Number:... Date of Detection:... Detected by:... Description of Minor Defects: Shows information such as Equipment Name Control Number Date Detected Detected by Description of defect Red Tags

10 1. Minor Flaws 2. Unfulfilled basic conditions 3. Inaccessible places 4. Contamination sources 5. Quality defect sources 6. Unnecessary and non urgent items 7. Unsafe places

11 Minor Flaws. Contamination. Damage. Play. Slackness. Dust, dirt, powder, oil, grease, rust, paint. Cracking, crushing, deformation, chipping, bending. Shaking, falling out, tilting, eccentricity, wear, distortion, corrosion. Belts, chains. Abnormal Phenomenon. Unusual noise, overheating, vibration, strange smells, discoloration, incorrect pressure. Adhesion. Blocking, hardening, accumulation of debris, peeling, malfunction. Unfulfilled Basic Conditions. Lubrication. Lubrication Supply. Oil level gauges. Tightening. Insufficient, dirty, unidentified, unsuitable leaking. Dirty, damaged or deformed lubricant inlets, faulty lubricant pipes. Dirty, damaged, leaking, no indication of correct level. Nuts and bolts slackness, missing, cross-threaded, too long, crushed, corroded, unsuitable washers, wing nuts on backwards. Aim and benefit of One Point Lessons and tagging of abnormalities is to prevent forced machine breakdown Forced machine breakdown is caused by the listed abnormalities

12 Inaccessible Places. Contamination Sources. Cleaning. Checking. Lubricating. Tightening. Operation. Adjustments. Product. Raw Materials. Lubricants. Liquids. Scrap. Others. Machine construction, covers, layout, footholds, space. Construction, covers, layouts, footholds, instrument position and orientation, operating range display. Position of lubricant inlet, construction, height, footholds, lubricant outlets. Covers, construction, layout size, space. Machine layout, position of valves, switches and leavers, footholds. Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum gauges. Leaks, Spills, Spurts, Scattering, Overflow. Leaks, Spills, Spurts, Scattering, Overflow. Leaking compressed air, gases, steam, vapors, exhaust fumes. Leaking water, Hot Cold, half finished products, waste water, leaking supply lines. Flashes, cuttings, packaging materials and non conforming product. Contaminants by people and forklifts, infiltration through cracked walls, broken windows. Aim and benefit of One Point Lessons and tagging of abnormalities is to prevent forced machine breakdown Forced machine breakdown is caused by the listed abnormalities

13 Foreign Matter. Shock. Moisture. Gain Size. Quality Defect Sources. Concentration. Viscosity. Machinery. Dust, rust, powder, chips, moisture, wire, scraps, wood pieces, paper pieces, stones. Dropping, Jolting, collision, vibration. Too little of too much infiltration. Abnormalities in screens, compressed air separators, centrifugal separators. Inadequate warming, heating, compounding, mixing, evaporation, stirring. Inadequate warming, heating, compounding, mixing, evaporation, stirring. Pumps, fans, compressors, columns, tanks. Unnecessary and Non- Urgent Items. Piping Equipment. Measuring Instruments. Electrical Equipment. Jigs and Tools. Spare parts. Pipes, hoses, ducts, valves, dampers. Temperatures, pressure gauges, vacuum gauges, ammeters. Wiring, piping, power leads, switches, plugs. General tools, cutting tools, jigs, dies, frames. Standby equipment, spares, permanent stock, auxiliary materials. Makeshift Repairs. Tape, string, wire, metal plates. Aim and benefit of One Point Lessons and tagging of abnormalities is to prevent forced machine breakdown Forced machine breakdown is caused by the listed abnormalities

14 Floors. Steps. Lights Unevenness, cracked, holes, projections, peeling, wear of steel chucker plates, slipping. Too steep, irregular, slipping, missing handrails. Dim, out of position, dirty and broken covers, no explosion proofing. Unsafe Places. Rotating Machinery. Displaced, fallen oil or broken covers, not safe for emergency, missing emergency stop devices. Lifting Devices. Wires, hooks, brakes and other parts of cranes and hoists. Others. Special substances, solvents, toxic gases, insulating materials, danger signs, protective clothing. Hindsight Engineering; if only we had..

15 Clean and inspect the selected equipment make use of the 5 senses and record the cleaning time. Determine the abnormalities make use of the 7 types of Abnormalities. Locate tags on abnormalities. Prepare a list of unfilled basic conditions. Compile a list of hard to clean, lubricate, tighten, inspect and adjust. Carry out an audit on the 1st Step. Carry out a meeting after the daily activities.

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17 Operational range Directional flow indicators

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20 TPM Training Schedule Participants: AIDC Team, Senior Management Team, Production Team. Aim: To present the fundamentals of Autonomous Maintenance and start company s journey through Total Productive Maintenance. Training Schedule: Step 0 theory Step 0 practical training Step 1 theory Step 1 practical training Step 1 closing and findings discussion 30 Minutes 1 Hour 1 Hour 1.5 Hours 30 Minutes Followed up with daily cleaning and weekly meetings Revision /01/14