Focussed Improvement

Effective Maintenance

Education and Training

Early Management

Quality Maintenance

TPM in Administration

Safety, Health,
Environmental

Autonomous
Maintenance

Autonomous Maintenance

- Step 0
5S

Total productive
Maintenance

Introduction Total Productive

Maintenance
Definition: A structured approach that establishes a corporate
culture, that will maximise production system effectiveness
TPM:
Total Involvement of all functions and
people at all levels of organisation
Productive Efficient and effective
utilisation of all resources
Maintenance Keeping the manmachine-material system in optimal

condition

Aim of TPM:
Prevent losses and achieve:
Zero Accidents
Zero defects
Zero Breakdowns
in the entire production system life

Introduction Autonomous Maintenance

Autonomous according to the dictionary means
independent, self-sufficient or self-governing
AM is the foundation stone of TPM
Activities by Operators to create & maintain base
conditions for optimal operation.
Without operators who can look after their own machines,

losses and break-downs cannot be reduced.

It is a way to secure improvements.

I am in charge of my machine

Objective

Problems that stop or slow the machine can be

eliminated by changing the attitude of the people

Managers, Operators & Technicians In other words
Zero Defect & Zero Breakdowns can be attained
When:
equipment works better, people work better
people work better, factory works better

factory works better, people are happier

7 STEP Implementation
Steps

Levels
7. Autonomous
Management

6. Standardization

5. Autonomous inspection

4. General Inspection

3. Develop tentative standards of cleaning,

inspection & lubrication

2. Counter measures against sources of dirt & difficult

points

Stage-3

Standardize maintenance
activities & implement
Autonomous Control
Stage-2
Assessment of the wear on
equipment & Develop activities
to prevent it

Stage-1
Establish Basic Conditions
of the Equipment & Maintain
those conditions

1. Initial Cleaning

0. Preparation

Get people motivated

Example of Implementation

Issues that Impact OEE

Low operative
efficiency

GHEE, THE MARKERS ARE NOT

GETTING BETTER

High # of damages
Deficient
communicacition

LACK OF
INTEREST

High N of accidents
DIFFICULTY
TO MAKE OUT

Lack of interest of
the operators

LOSSES DUE TO SETUP

LOSSES DUE TO DEFECT

Lack of skills

LOSSES DUE TO RAW MATERIAL

LACK OF
SKILL

Issues of Prod & Maint.

OPERATOR

Selfish attitude

I OPERATE, YOU REPAIR

MAINTENANCE
STAFF

Negative attitude

BE GREATFULL THAT I FIXED YOUR MACHINE

NON PRODUCTIVE MAINTENANCE

TPM View

Baby

Machines

Parents

Operators

Physicians

Maintenance

Operators Should Be Able To

Understand how the equipment works & identify the causes

of abnormality
Identify & correct equipment abnormalities
Understand the relationship between equipment condition &
quality of the product; i.e. foresee quality issues & recognize
the cause.
Carry our repairs
Take charge of making improvements; on their own &
through working with other departments

Autonomous Maintenance Step 0

Step 0 - Initial Preparation

Problems and equipment abnormalities cannot be clearly seen
when the workplace is unorganized.
Cleaning and organizing the workplace helps the team to uncover
problems.
Making problems visible is the first step of improvement.
5s is a foundation program before the implementation of TPM
To make the workplace organised and neat, 1S and 2S needs to be
implemented

Step 0 1S Sorting the Work Place

1S (Seiri/Sorting)
- 1.) Classify

necessary &
unnecessary
tools
and
equipment around
Work
Station

- 2.) Clear out unnecessary

items, take them to salvage
area or store

- 3.) Sort:
-

Hand Tools
Gauges
Equipment Accessories
Spares
Cupboards and work
tables

Step 0 1S Sorting the Work Place

1S (Seiri/Sorting)

Step 0 1S Sorting the Work Place

Decision Matrix

Step 0 2S Organising the Work Place

2S (Organising)
- 1.) Decide

the right
place for each necessary
item (location)

- 2.) Mark

the locations by
drawing a boundary around
the equipment to indicate its
zone

- 3.) Exhibit:
-

Equipment Running
Job Change
Tool Change
Break Down

Step 0 2S Organising the Work Place

2S (Organising)

Summary

Autonomous Maintenance

Operator takes ownership of his/her equipment at all times

Establish basic conditions of equipment

1S Sorting

Classify needed and unneeded items in

work area

Clear out unneeded items in work area

2S Organising

Create a place for every needed item in

workplace

Pre-fixed locations of tools and

equipment

Standardise the item location and sustain

it