自主维护保养教程推行全员参与自主维护保养的程序及推行思路.ppt

autonomous maintenance,learning objective,understand the autonomous maintenance performance expectations for: program implementation progress measurement stages and steps,effectiveness of line team meetings,our line teams meet once a month to review performance at these meetings, operators often raise issues the meetings could be more effective we need to formalize the agenda and process to capture, prioritize and address problems in accordance with business needs,topic 2: autonomous maintenance implementation,implementation plan performance expectation,identify natural work teams (natural team & equipment-based team) define roles and responsibilities identify line sponsors(work area team leader/s&c), line owners(operator with enough knowledge and leadership skills), and support resources (s&c ) conduct small group meetings (twice a month) create a project plan (an action plan for each natural team through 7 steps),sgm is used to complete any of the following activities:,review and analyze equipment losses. review status of action items on equipment problems and defects list. conduct root cause analysis on a specific problem and develop a recommended action plan. conduct training on a new topic or reinforce existing programs (e.g., equipment, new job responsibility, 5s & visual workplace, safety, quality). review and refresh sops. capture improvement suggestions. identify issues that should be elevated as maintenance requests. review standard work instructions (ppms, one point lessons, etc.).,problem tags performance expectation,shift, date, individual who found problem location, system, equipment, part id problem type operation type possible impact possible corrective action root cause,prioritizing corrective actions performance expectations,helps teams identify and act on equipment problems groups problems and defects (defective areas, questions, sources of contamination and inaccessible areas) should be completed and updated for each piece of equipment,topic 2: review,develop a 3 year plan identify natural work teams identify roles and responsibilities for each work team identify sponsors, leaders and support resources distribute and train on: problem tags equipment problems and defects list,topic 3: autonomous maintenance stages and steps,step 3 standardize cleaning, inspection and lubrication procedures,step 2 eliminate contaminant sources and inaccessible areas,step 5 operators inspect, clean, lubricate and conduct basic maintenance,establish equipment basic condition,step 7 operators participate in continuous improvement activities,step 6 operators are responsible for some aspects of the physical organization and management of the workplace,step 4 train operators to conduct daily inspection and basic maintenance,step 1 complete initial deep cleaning,stage 1: establish basic equipment condition,step 3 standardize cleaning, inspection and lubrication procedures,step 2 eliminate contaminant sources and inaccessible areas,step 5 operators inspect, clean, lubricate and conduct basic maintenance,establish equipment basic condition,step 7 operators participate in continuous improvement activities,step 6 operators are responsible for some aspects of the physical organization and management of the workplace,step 4 train operators to conduct daily inspection and basic maintenance,step 1 complete initial deep cleaning,step 1: initial deep cleaning performance expectation,training is the first step allows for close inspection of the equipment and its parts can quickly distinguish abnormal operation understand business impact,step 1: initial deep cleaning performance expectation, continued,problem identification form teams for specific equipment ensure that the team understands cleaning is inspection, inspection leads to defect detection, and detection leads to correction of defects follow safety rules use the equipment problems and defects list and problem tags,step 1: initial deep cleaning performance expectation, continued,problem resolution prioritize opportunities address questions promptly update the equipment problems and defects list equipment condition (initial cleaning) conduct for all equipment inspect for missing or loose parts or components,step 2: eliminate contaminant sources performance expectation,identify and eliminate sources of contamination identify and eliminate inaccessible areas prioritize corrective actions based on business impact,step 3: standardize procedures performance expectation,design standard work instructions (swis) for cleaning, inspection and lubrication use sops, one point lessons and process picture maps (ppms) use visual aids to communicate procedures,stage 2: daily inspections and basic maintenance,step 3 standardize cleaning, inspection and lubrication procedures,step 2 eliminate contaminant sources and inaccessible areas,step 5 operators inspect, clean, lubricate and conduct basic maintenance,establish equipment basic condition,step 7 operators participate in continuous improvement activities,step 6 operators are responsible for some aspects of the physical organization and management of the workplace,step 4 train operators to conduct daily inspection and basic maintenance,step 1 complete initial deep cleaning,step 4: daily inspection and basic maintenance performance expectation,operators should understand how the equipment functions basic lubrication machine elements (fasteners) pneumatics hydraulics electrical systems power transmission drives train operators in basic maintenance,step 5: operator accountability performance expectation,select maintenance tasks should be moved from maintenance to operations compare tasks completed by operators and mechanics agree to those that can be moved develop swis (standard work instruction),stage 3: drive continuous improvement and quality,step 3 standardize cleaning, inspection and lubrication procedures,step 2 eliminate contaminant sources and inaccessible areas,step 5 operators inspect, clean, lubricate and conduct basic maintenance,establish equipment basic condition,step 7 operators participate in continuous improvement activities,step 6 operators are responsible for some aspects of the physical organization and management of the workplace,step 4 train operators to conduct daily inspection and basic maintenance,step 1 complete initial deep cleaning,step 6: operator ownership performance expectation,train operators develop swis budget time conduct formal meetings,new responsibilities spare parts management (nuts, bolts, “o” rings, etc.) changeover execution and improvement 5s and visual workplace maintain standard procedures on-line quality maintenance notifications,step 7: ownership of additional responsibilities performance expectation,participate in continuous improvement projects minor maintenance improvement of maintenance plans equipment redesign/design,7 steps divided into 3 stages complete deep cleaning eliminate sources of contaminants standardize procedures implement basic maintenance training for operators select basic maintenance tasks to be moved to operations evaluate additional operator responsibilities (qc inspections and changeovers) incorporate operators in continuous improvement discussions to build ownership,topic 3: review,topic 4: progress measurement,progress measurement autonomous maintenance metrics,monitoring progress performance expectation,am step progression checklists natural team completes self-assessment work area