AUTONOMOUS

MAINTENANCE

STEP 2
AUTONOMOUS MAINTENANCE
STEP 2
OEE Calculations
Eliminate sources of contamination
Eliminate obstacles to effective
cleaning
Follow up on issues from Step 1
Encourage proactive approach to PM
 OEE
OVERALL EQUIPMENT EFFECTIVENESS

Excellent measurement tool

Makes it easy to determine biggest loss
Should be placed on activity board
 SIX BIG LOSSES
BREAKDOWNS
AVAILABILITY
SET-UPS & ADJUSTMENTS

REDUCED SPEED
PERFORMANCE
MINOR STOPPAGES

DEFECTS & REWORK

QUALITY
START UP AND YIELD LOSSES
AVAILABLE PERFORMANCE QUALITY

80%

x 78%
x 82%

80% x 78% x 82% = 51%

 OEE CALCULATION
Availability = Available Time - Downtime x 100
Available time
EXAMPLE:
Availability = 460 minutes - 60 minutes x 100 = 87%
460 minutes
Ideal cycle time x
Performance = Processed amount x 100
Rate Operating time
EXAMPLE: 0.5 minutes/unit x
Performance 400 units x 100 = 50%
Rate 400 minutes

Processed Amount --
Quality = Defect Amount x 100
Rate Processed Amount

EXAMPLE:
Quality = 400 units -- 8 units x 100 = 98%
Rate 400 units
 EXAMPLE

OVERALL EQUIPMENT PERFORMANCE QUALITY

= AVAILABILITY X X
EFFECTIVENESS RATE RATE

EXAMPLE:
Overall Equipment Effectiveness = 0.87 x 0.50 x 0.98 x 100 = 42.6
 STEP 2
Elimination of Sources of Contamination and Inaccessible areas

Introduces operators to equipment

improvement activities
Focuses on eliminating obstacles to effective
cleaning and inspection
Follows up on observations and issues
arising during Step 1 Initial Cleaning
Encourages a proactive approach to more
effective routine preventive maintenance.
 PURPOSE OF STEP 2

Prevent deterioration by stopping the spread of

contaminants at their source and facilitating
preventive checks.
Make cleaning and inspection easier to do, more
thorough and less time-consuming.
Encourage operators to use their creativity to control
equipment and environmental conditions.
Improve accessibility for lube and cleaning
Insure improvements become part of early equipment
management
 STEP 2 ACTIVITIES
Inspect machines to find locate sources of
contamination and inaccessible areas.
Team should brainstorm methods to control the
contamination and those improvements needed to
make cleaning easier
Make revisions to shorten inspection, lubrication, and
cleaning time
Share revised methods with other teams
Continue to improve Step 1 cleaning and inspections
and follow up on any unresolved problems
 TARGET AREAS

Areas that get dirty or contaminated

immediately after initial cleaning
Area it takes a long time to clean or
inspect
Parts of the machine that are hard or
impossible to inspect while machine is
running
 EXAMINING ROOT CAUSE
Why? Why? example
1. Clarify the problem
oil leaks into the main electrical panel on the press
2. Ask why the problem occurs:
Q: Why is there oil leaking into the main electrical panel?
A: The door will not close properly.
3. Ask why again until you find the level of effective preventive action
Q: Why will the door not close properly?
A: Because the door is continually being smashed by the
scrap buggy
Q: Why is the scrap buggy continually smashing the door?
A: There is nothing to restrict its movement from hitting the door.
Solutions:
Have a stop made from angle iron placed on the floor to prevent the
scrap buggy from being pushed into the junction box.
CONTAMINATION IMPROVEMENTS

Leaking or spattered Repair leaks, make

fluids sure seals work, control
overflows
Dirt caused by wear
Install shields to control
and cutting spatter and debris from
Dirt and dust from cutting
external sources Install dirt, dust, and
mist collectors
Come up with efficient
washing methods that
do not spread
contaminates
 ELIMINATE INACCESSIBLE
AREAS
Parts located too close to ground for
inspection or changing of filters
Parts hidden by covers that cannot be
removed easily or during operation
Parts or areas obscured by hoses or
pipes.
 IMPROVEMENTS
Relocate parts which are hard to inspect
or change filters
Cut windows in covers, install simpler
hinges and fasteners on covers
Simplify hoses and piping to make
areas more accessible
 ONE POINT LESSON
A single topic on a single sheet of paper
that can be covered in 10 min. or less.
Two types
- Basic lesson
- Improvement bulletin
AUTONOMOUS
MAINTENANCE

STEP 3
 INTRODUCTION
During this phase of the Autonomous
Maintenance process, we will begin
developing the standards for cleaning,
lubricating and inspecting. These
standards will be developed by the
teams and not management. This will
assure realistic standards and promote
by-in by all operators.
ACHIEVING ZERO BREAKDOWNS
Restore equipment to original state, do not allow
deterioration to continue
Maintain basic machine conditions
- cleaning
- lubrication
- inspection
Stick to the standards
Sharpen operations and maintenance skills
Do not stop with emergency fixes, use aggressive
corrective action
Machine must be put into original operating condition
before making changes to the process (you cannot
judge what is needed until the machine is operating
correctly)
 GOALS OF STEPS 1-3

Step 1 is to stabilize equipment condition through

cleaning and checking
Step 2 is to stop accelerated deterioration, make
machines easier to clean and inspect
Step 3 is to control and prevent further deterioration
by apply and using standards
These three steps are the foundation for stopping
and controlling deterioration on equipment
 TEAMWORK

Putting people in groups does not make them a team

Definition
- A group of highly motivated individuals working together to achieve
a common goal
The whole is greater than the sum of its parts
Teams need the following:
- A method for determining what to work on
OEE helps address this
- Concrete targets and completion dates
- Support and resources
- Training in team processes
- Rewards and feedback for accomplishments
 TOOLS FOR TEAMS
Activity Boards
What should be on activity boards
Theme and goal
Before and after pictures
Team name and picture
Abnormality summary and tags
OEE chart
One point lessons
Why-Why example
Improvement bulletins
Pareto Charts
Lubrication Charts
Meetings
Keep short and hold frequently
Have an agenda
One point lessons
 STEP 3 ACTIVITIES
Learn how to do lubrication checks and tasks needed to
maintain basic machine conditions
Standardize cleaning, lubrication and inspection tasks
Formalize tasks in manual form to be followed according to
schedule set up by teams
Label lubrication inlets and inspection area using visual
controls
- Color code and label lubricant inlets
- Label lubrication levels
- Mark grease locations
Organize needed lubricants and tools
 PURPOSE OF STEP 3
ACTIVITIES
Assure that conditions established in
step 1 and 2 are maintained for the life
of the machine
Assure that basic machine conditions
are maintained through proper
lubrication
Give teams the opportunity to set
realistic goals and support ownership of
the process
 VISUAL CONTROLS
Insure mistake proofing of process
Get appropriate information as close as
possible to point of action
Ask what needs to be controlled and
how can we control it simply and
visually
 KEYS TO SUCCESSFUL
STANDARDS
Education: (operators must understand
importance)
Empowerment: People doing the work must
set their own standards in their own words
Improvement: Equipment must be improved
to make adherence to standards easier
Planning: Time necessary to carry out
standards must become an official part of the
daily schedule
Management: Standards must be clear and
easy to understand so they will be done
 GUIDELINES
Specify:
- lube site
- type and amount of lube
- what to use (tools) and how to add
- schedule
- who is responsible
Identify inspection items and judgment
criteria
List all tasks in an efficient and orderly
manner
Make sure the standards are clear and
easy to understand by everyone
 STANDARDS MANUAL

Developed by teams
Organizes all standards in manual form
Expand on different parts and areas to
make identification easy
Keep manual at machine and easily
accessible for frequent use
Use sheet protectors to keep manual
readable