Operator Asset Care Autonomous Maintenance T.P.M.

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1 Operator Asset Care Autonomous Maintenance T.P.M. Improved Reliability through Operator Care Copyright SIRFRt, 2015

2 AGENDA What is TPM or Operator Asset Care? Why OAC or TPM? The goals of TPM The 7 Steps of TPM Lessons from Implementation ALCOA AMCOR SIRF member companies

3 TPM Total Productive Maintenance Total Productive Maintenance Everyone, Every Where, Every Day Eliminate ALL accidents ALL defects ALL breakdowns No Waste Often while machine is running Equipment As New Better than As New

4 Focused Improvement-Kaizen Autonomous Maintenance -TPM Planned Maintenance Training and Education Early Management Quality Maintenance Safety Health & Environment Office TPM 8 Pillars of TPM Source: JIPM

5 What is Autonomous Maintenance? Autonomous means Self Reliant Autonomous Maintenance means first line maintenance performed by equipment operators Source: Nippondenso

6 Operator Asset Care Keep Machines Healthy PREVENT PROBLEMS MEASURE, MONITOR and INSPECT for PROBLEMS HELP SORT OUT PROBLEMS Operate Correctly Clean Regularly Lubricate Tighten Measure & monitor Inspect Record Report breakdowns and problems promptly Minor repairs Assist trades in major repairs Joint problem solving

7 Autonomous Maintenance At home & at your factory At home At your plant Fuel Check oil & coolant level Check air pressure Cleanliness Check hydraulics pressure Check lights Cleanliness Tire Pressure Check lubrication

8 The Operator is the Best Condition Monitor Competent trained operators and their 5 senses Monitoring equipment condition Speaking up for any abnormality Knowing what to do in event of abnormality

9

10 Improved Maintenance Effectiveness Results in Reduced Costs 40% Maintenance Costs Equipment Reliability Labor Effectiveness Customer Satisfaction Skills Capability Morale Contractor Services Spare Parts Costs Emergency Maintenance Breakdown Reactive Preventative Predictive Best Practices Maintenance Assessment Score

11 Reliability is a Partnership Production and maintenance as ONE TEAM working towards a common goal

12 7 Steps of TPM (Autonomous Maintenance) 7. Full Self Management 6. Workplace management and control 5. Autonomous Inspection 4. General Inspection 3. Provisional Standards - Lubrication - Cleaning 2. Eliminate Contamination Sources and Hard to Access or Clean Areas 1. Initial Cleaning

13 Which is better? Automatic Car Wash or Hand Washing

14 TPM Blitz Spectaculars PLANNING LEADERSHIP EVERYONE TEAMWORK FUN REPAIR in the moment FOLLOW UP STANDARDISE

15 STEP 1- Initial Cleaning To return the machine to new or better than new. to enable problems to be easily seen upon inspection to allow leaks, contamination and looseness to be seen so that these can be contained or removed fixed forever Cleaning with Meaning Clean to Inspect Inspect to Detect Detect to Correct Correct to Perfect

16 RAISED PLANNED COMPLETE

17 7 Steps of TPM (Autonomous Maintenance) 7. Full Self Management 6. Workplace management and control 5. Autonomous Inspection 4. General Inspection 3. Provisional Standards - Lubrication - Cleaning 2. Eliminate Contamination Sources and Hard to Access Areas 1. Initial Cleaning

18 Step 2 Eliminate Sources of Contamination, Eliminate leaks, Enable Access to all Areas Reduce or contain contamination and leaks at the source Enable access to clean and inspect all areas of the machine Make cleaning, inspection, and lubrication easier and less time consuming for maintenance and operators IMPROVE!

19 Level 2: GOALS Reduce the time it takes to clean, check and lubricate Prevent leaking, spilling, spraying or scattering of: Product Lubricant Hydraulic fluid Powders Vapours Other process material Improve accessibility of places that are difficult to: Clean Check Lubricate Tighten Operate Adjust

20 Level 2: Pinpoint & eliminate sources of leaks Work in small improvement groups, together with production, maintenance and engineering Use 5 Why s to find the root cause of the problem Make a plan to solve the problem Look for simple improvements, such as covers or canals to drain excessive fluids

21 Strategies to eliminate sources of contaminations 21

22 TPM Level 2 Examples of Bad Access A simple door will improve our access

23 Autonomous Maintenance Step 2: Improve inspection

24 7 Steps of TPM (Autonomous Maintenance) 7. Full Self Management 6. Workplace management and control 5. Autonomous Inspection 4. General Inspection 3. Provisional Standards - Lubrication - Cleaning 2. Eliminate Contamination Sources and Hard to Access Areas 1. Initial Cleaning

25 STEP 3 Establish Cleaning and Lubrication Standards Goal : to keep our equipment in clean condition Standards What Where When Who How Test

26 Standardise No improvement without Standardisation No Standardisation without Leaders Standard Work to support the operators standard work Cascaded Audits

27 TPM Lubrication Requirements Tonne Splay Press Lubrication Chart RELIABILITY FOR OPERATORS Clear colour-coded graphic layout of the machine All lubrication and filter points Component identification Recommended lubricant Quantity of lubricant Frequency of lubrication

28 Colour coded lube: At Storage Transport Oil Can On Cap at point of use

29 7 Steps of TPM (Autonomous Maintenance) 7. Full Self Management 6. Workplace management and control 5. Autonomous Inspection 4. General Inspection 3. Provisional Standards - Lubrication - Cleaning 2. Eliminate Contamination Sources and Hard to Access Areas 1. Initial Cleaning

30 Step 4. General Equipment Inspection Operators are trained to conduct routine inspections on their equipment to identify and correct minor defects to help find ways of making inspections easy On the job training, visual control

31 Improve understanding of equipment RELIABILITY FOR OPERATORS TRAINING WITH ENGINEERING STAFF In the class room On the shop floor Process and Instrumentation Diagrams Fault Tree Diagrams Regular discussion re Process and Equipment Problems

32 Training program example RELIABILITY FOR OPERATORS Cavitation Loss of performance and efficiency Damage to the impeller Vibration and damage to bearings Seal water Bearings Leaks Excessive Amps No water failure of seal Poor or no lubrication bearing failure Faulty discharge seal Imminent bearing / seal failure Vibration / Heat Imminent failure

33 Step 4. General Equipment Inspection See something wrong Smell something wrong Source: NipponDenso Feel something wrong Feel something wrong

34 Normal Run Valve Positions COLOUR CODED BLUE = Variable / Adjustable GREEN = Normally Open RED = Normally Closed Source SCA SIRF NZ Workshop

35 The 4 Lists RELIABILITY FOR OPERATORS 1 Defects 2 Difficult to Access Areas 3 Sources of Filth or Contamination 4 Questions

36 7 Steps of TPM (Autonomous Maintenance) 7. Full Self Management 6. Workplace management and control 5. Autonomous Inspection 4. General Inspection 3. Provisional Standards - Lubrication - Cleaning 2. Eliminate Contamination Sources and Hard to Access Areas 1. Initial Cleaning

37 Step 5. Autonomous Inspection Review of cleaning, lubrication and inspection standards for improvements. Goal to promote standardization and develop skilled equipmentknowledgeable operators. Inspection Standards & Breakdown Analysis Revise Standards & Review Skill Levels Operators know their Maintenance OEE Increases

38 Equipment Goals Machine in Top Condition and in control Step 5 Autonomous Inspection Step 4 General Inspection Step 3 Lubrication and Cleaning standards defined. Maintain equipment in control Step 2 Improve Access and eliminate or control contaminants Step 1 Clean to Inspect and Detect People Goals Operators with skill so they are able to keep the machine in control

39 Achieving the balance INSPECTIONS RELIABILITY FOR OPERATORS SELL Maintenance Safe, Economical, Legal, Logical TLC Tighten, Lubricate, Clean Adjust, Changeover Maintenance Operators 10:1 inspections

40 7 Steps of TPM (Autonomous Maintenance) 7. Full Self Management 6. Workplace management and control 5. Autonomous Inspection 4. General Inspection 3. Provisional Standards - Lubrication - Cleaning 2. Eliminate Contamination Sources and Hard to Access Areas 1. Initial Cleaning

41 Data Step 6. Workplace management and control 5S Visual Factory Visual Control Move from beyond equipment focus to total work area Standardize: Set Up and Change Over Times Work in Progress Spare Parts / Tools

42 7 Steps of TPM (Autonomous Maintenance) 7. Full Self Management 6. Workplace management and control 5. Autonomous Inspection 4. General Inspection 3. Provisional Standards - Lubrication - Cleaning 2. Eliminate Contamination Sources and Hard to Access Areas 1. Initial Cleaning

43 Step 7. Fully Autonomous Maintenance Continuous Improvement Self Reliant Maintenance perform minor repairs

44 Communication

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