Autonomous

Maintenance
for Operators
Chapter 1

Becoming Equipment
Conscious Operators

Autonomous Maintenance
Autonomous = independence
The activities designed to
involve operators in
maintaining their own
equipment
AM helps operators become
equipment conscious

Equipment Conscious Operators

Equipment Conscious
Operators are more than
finger pointers
Ability to discover
abnormalities
Ability to correct
abnormalities
Ability to set optimal
equipment conditions
Ability to maintain optimal
equipment conditions

Ability To Detect Abnormalities

Its easy to identify
Functional breakdowns
Defects

Operators need to be able

to recognize abnormal
conditions before the
machine breaks down
Sounds
Sights
Smells

Ability To Correct Abnormalities

& Restore Function
2nd essential skill of
an Equipment
Conscious Operator
is the ability to correct
Even if we cant fix it,
we must be able to
clearly explain what
happened

Ability To Set Optimal

Equipment Conditions
3rd essential skill of an
Equipment Conscious
Operator is the ability to set
conditions and standards
Standards should allow you to
determine, quantitatively, if the
equipment is functioning
normally

Becoming Equipment
Conscious Operators
Skill Level 1: Recognizing
Deterioration & Improving
Equipment to Prevent It
Recognizing that deteriorated
equipment conditions are a
problem
Mastering the basics of
equipment improvement
Encourages operators to
treat their machines as
partners

Becoming Equipment
Conscious Operators
Skill Level 1:
Hands-on cleaning,
inspection & lubrication
leads to discovery of
deterioration
Hands on also allows us
to discover simple ways
to prevent recurring
problems

Becoming Equipment
Conscious Operators
Skill Level 2:
Understanding Equipment
Structure & Function
Understanding vital
mechanisms of the
machine and keeping
them running flawlessly
Mechanical Diagrams &
Lubrication Maps to
illustrate where attention
is needed

Becoming Equipment
Conscious Operators
Skill Level 3:
Understanding The
Causes of Quality Defects
Operators learn to think
logically about how
defects occur
Operators monitor defect
trends as it pertains to
TPM activities

Becoming Equipment
Conscious Operators
Skill Level 3:
Level 2 Operators focus on
preventing malfunctions that
cause breakdowns
Level 3 Operators focus on
preventing malfunctions that
cause deterioration and
quality defects

Becoming Equipment
Conscious Operators
Skill Level 4: Performing
Routine Repairs
First learn how equipment
functions
Second how to find breakdown
abnormalities
Third how to find quality
abnormality
Level 4 we learn simple
disassembly and repair
Torque bolts properly
Align pulleys & gears
Changing Bearings

Chapter 1 Summary
Autonomous Maintenance
is to equip operators with
skills and abilities to help
prevent machine
breakdowns and quality
defects.
There are 4 Skills in
becoming Equipment
Conscious Operators
Companies and people
grow together

Autonomous
Maintenance
for Operators
Chapter 2
Cleaning is Inspection

Initial Cleaning Is The

Foundation Of AM
Cleaning is Inspection
Inspection is finding
problems
Problems demand
restoration to prevent
recurrence
Initial Cleaning could be
the most important step
in AM

When You Find A Problem, Tag It?

Removing years of gunk will
reveal problems
Attach a tag to each problem
you expose so it wont be
forgotten
Fix problems as soon as
possible
Develop a plan for resolving
problems that cannot be
addressed immediately

Common Problems
Static & Dynamic Problems
Dirt & grime
Leaks or contamination
Missing parts
Warping or wear
Rust
Off centered parts
Abnormal movement
Excessive vibration
Unusual sound or heat
Discoloration

Sample Inspection
Checklist for a Hydraulic Unit

Sample Inspection
Checklist for a Hydraulic Unit
1. Look
Is the hydraulic unit dirty
with chips or cutting oil?
Is oil leaking from pumps,
solenoids valves, etc.?
Are oil level gauges clearly
visible?
Is there the right amount
of hydraulic oil?
Are the inlet caps on tight?

Sample Inspection
Checklist for a Hydraulic Unit
2. Listen
Are there any strange
noises from the pumps,
motors, solenoids valves,
plumbing or any other
machine elements.

Sample Inspection
Checklist for a Hydraulic Unit
3. Touch
Are there any unusual heat
or vibration from pumps,
motors or solenoid valves?
Are lock nuts coming
loose?
Has the oil been wiped off
to confirm leaks?
Do hoses cross or touch
one another?

Sample Inspection
Checklist for a Hydraulic Unit
4. Disassemble
Are there any signs of
wear in motor or pumps
couplings?
Are the vents on oil inlet
caps in good condition?
Are oil inlet overflows
broken or dirty?
Has dirt accumulated
inside of tanks?

Sample Inspection
Checklist for a Drive System

Sample Inspection
Checklist for a Drive System
1. Look
Have chips or cutting oil
contaminated the motor or
brake?
Are belts wobbling or at the
right tension?
Is the brakes oil-level
gauge readily visible?
Are belts and pulleys
shielded by safety guards
that permit easy checking?

Sample Inspection
Checklist for a Drive System
2. Listen
Are there any strange
noises (whining, groaning,
or sounds of slippage) from
the motor, brake, belts or
chains?

Sample Inspection
Checklist for a Drive System
3. Touch While In Operation
Is there vibration from the
motor or brake?
4. Touch While Off
Are the volume and color of
oil satisfactory?
Are safety guards fastened
securely?
Are the motor and brake
mounting bolts tight?

Sample Inspection
Checklist for a Drive System
5. Remove Covers & Verify
Are belt tensions
satisfactory?
Are belts or pulleys worn?
Are the motor and the
brake properly aligned?
Is there debris in the motor
cooling fan?
Is there any debris in
brake lubricant?

Cleaning Motivates People To Take

Action & Care for Machines
Machines will get dirty
again
Through deep cleaning
and detection, we will
want to find ways to keep
the machine from getting
dirty
This motivation will lead
to ideas and better ways
to contain debris to
eliminate cleaning

Tips For Cleaning

Dont be afraid to get your
hands dirty
Dont just surface clean
Clean hard-to areas
Dont just clean the main
body of the machine
Conveyors, gauges, electrical
cabinets

Focus on where and when

the contamination begins
Dont do the job halfway

Tips For Inspection

Dont stop at obvious problems
you can see
Look for loose fastenings,
vibrations, abnormal
temperatures
Look for worn pulleys and belts,
loose chains and worn
sprockets
Find sources of air and oil leaks
Are cleaning, lubrication &
inspection points easy to
access?

Chapter 2 Summary
Initial cleaning is the heart of
AM
Initial cleaning means cleaning
all static and dynamic
problems
When tagging abnormalities,
the person applying the tag
should be the one to remedy
and remove it
The more we clean, the more
we will want to find ways to
keep equipment from getting
dirty again

Autonomous
Maintenance
for Operators
Chapter 3
Using Localized Containment

What is Accelerated Deterioration?

Natural Deterioration
Happens whether or not
equipment if used correctly

Accelerated Deterioration
Caused by failure to do
maintain our equipment
Neglecting a machines basic
needs

Containment

The Trouble with Large Enclosures

Chips, oil, wood, wet-type
processes are leading cause of
Accelerated Deterioration
Use of machine enclosures are
used to control debris
What are some problems with
large machine enclosures?
Enclosures do nothing to prevent
actual deterioration
Make maintenance harder
Complicate changeovers

The Point of Containment

How should we contain our
debris?
Small localized guards that
cover the debris at the
source
Bring guards close together
as possible to contain the
debris and make it easy to
clean
This is Step 2 of AM

Tips for Containment

Check whether to coolant is
concentrated on the cutting
point
If its not, scatter gets worse,
tool life shortens and work
piece finish is poor
Understand the direction,
angle, volume and speed of
scattered material
Check the shape and size of
built in guards, see if they can
be improved

Continually Improving
Containment
The operator knows the most
about the scatter of debris
Operators with the help of
Maintenance should home
make covers to test
containment efforts
The team should study the
guard, its effectiveness,
adjust the design and correct
the problems
Build a long term guard after
corrections have been made

Benefits of Localized Containment

Accelerated deterioration
stops because dirt and grime
dont penetrate to critical
functioning parts
Cleaning can be performed
quickly
Lubrication & inspections
become easier
Setups go quicker because
the machine is clearer and
not obstructed by large
guards

Example: Milling Machine Guard

Operators originally made box

containment guards
Debris still piled up
Operators became frustrated and so
they just let the debris pile up and
then clean it at the end of the shift
which took 35 minutes per day
Lubrication tank was filled with
cutting debris and caused a
breakdown
Team then made rubber curtain type
shields

Decreasing Breakdowns & Defects

With Localized Containment

Localized containment is
essential
Natural deterioration will replace
accelerated deterioration
When you take the time to fix it
at the source, you will reduce
future breakdown
STOP IT!!!
What are some examples of
localized containment at your
plants?

Chapter 3 Summary
Accelerated deterioration happens as a results
from failure to do something you should
Keeping the work area clean is an important
concept in reducing accelerated deterioration
Two types of containment are shield-type and
box-type guards
Localized containment is a more effective
method for controlling debris than large shields

Autonomous
Maintenance
for Operators
Chapter 4
Lubrication Management
For the Shop Floor

Why Lubricate?
60% of breakdowns of moving parts
happen due to poor lubrication
What are some reasons lubrication
fails?
Failure to adhere to correct
lubrication standards
Absence of lubrication standards
Use of wrong standards
Getting rid of lubrication problems
starts by never running equipment
without lubrication standards

What is Lubrication
Management?
Lubricating Equipment
correctly and reliably
According to use
With proper lubricant
At designated inlets
At specified times
At specified amounts
What do we have to have to
ensure proper lubrication?

Grouping Lubricants

Using only the specified lubricants recommended

by the OEM would require a lot of stock
More lubricants increases the risk of grabbing the
wrong lubrication off the shelf

Grouping Lubricants
To group lubricants:
Make a list of lubrication brands
and types in use
Group lubricants that have
similar viscosity
For each group reduce the total
number of lubricants kept on
hand
Use multipurpose lubricants that
will work on multiple machines
(check w/OEMs)

Adding Lubricants
At The Right Time
Proper lubrication intervals
are crucial
Create Lubrication
Schedules
If the OEM gives no
guidance on lubrication
intervals, or your machine
doesnt have an operating
manual
Must set sensible standards
and verify lubrication
through trial

Adding The Right

Amount of Lubrication
Too much lubrication
can cause leaks, lower
viscosity & promote
deterioration of the
lubricant
Too little lubrication
case cause friction,
sticking and motor burn
out

Operator Responsibilities
& Lubrication Tips
Always keep the machines
lubrication and friction
surfaces clean
Keel lubrication containers,
tools well organized and clean
Make sure no debris or
moisture gets into lubricants
Dont mix lubricants, unless
required
Label lubrication sites with the
appropriate type and
frequency

Daily Lubrication Checks

Daily checks tell us a story about
normal operating conditions:
Is lubricant getting to the parts
(actually check periodically)?
Are lubricant quantities within limits?
Are there leaks?
Is there discoloration, clouding,
foaming?
Are there noises or vibrations?
Is the consumption rate higher or
lower than normal?

Setting Lubrication Standards

Standards need to include:
Inlet Locations
Method For Checking
Lubrication Method
Lubricant Type
Lubrication Tools
Time Needed To Lubricate
Lubrication Schedule
Person Responsible

Easing Lubrication Standards

The responsibility of
moving lubrication to
operator is huge
The easier you make it, the
better the transition will be
Color code lubrication
types and inlets
Combine zerks to a
centralized lubrication
system

Visual Management
Visual Management should
be used for lubrication
inlets, containers, tools
and practices:
Distinguish lubricants of
difference viscosities
Match inlets with grease
guns
Color coding helps
mistake proofing

Chapter 4 Summary
Poor lubrication of moving parts accounts
for 60% of downtime
The only way to Zero Defects and Zero
Downtime is a standardized Lubrication
Management System
Consolidate lubricants to reduce the
amount of stock
The right lubricant at the right time is
crucial

Autonomous
Maintenance
for Operators
Chapter 5
Activity Boards and Meetings

Autonomous Maintenance
& Team Activities
The goal of AM is for Maintenance
to help develop operators to have
strong machine related skills
What is the most crucial element
to make AM successful
TEAM WORK!!!
What does the teams success
depend on?

Support
Favorable environments
Motivation
Ability

Where does
Motivation Start?
Clearly Knowing:
What are we going to do?
(Theme)
Why are we going to do it?
(Vision)
How far are we going to go?
(Targets)
How are we going to do it?
(Method)

Where does
Motivation Start?
Clearly Knowing:
What is the sequence and
timing of actions?
(Schedule)
Who does what? (Roles)
What results are expected?
(Assessment)

The Activity Board: A Guide to Action

Activity Boards
communicate and translate
the Vision
Clarity is key
At a glance you can see
where you are
The same approach to a
sporting event can and
should be used at work

Giving Encouragement to the Team

The Activity Board should
always express support for
people and their hard work
Activity Boards that are
easy to understand will spur
members to keep up their
efforts (as long as there is
ownership & accountability)
Good Work, Way To Go
& Atta Boys go along way

Remembering the Goal

Activities should be evaluated:
Were the goals achieved
consistent with team objectives?
Did the activity resolve everything
or do problems still remain?
Was anything left undone?
Did the team run into any
problems?
What is the next step?

Using Activity Boards In Meetings

Activity Boards are an effective
way of showing what is current
and what needs to be done
Activity Boards helps team
members focus meetings on the
right issue
Activity boards can be
supplemented by One Point
Lessons (chapter 6)
Activity boards, meetings and
one point lessons are essential
tools of team activities

Keeping Minutes of Meetings

Minutes provide valuable
documentation of progress
After the meeting is over a
document should be
distributed that lists:

Date & time

Attendees & meeting Leader
Topics discussed
Decisions made
Actions to be taken

Rules For Meetings

Time is limited, stick to the
point (parking lots)
The team comes first, focus
on team goals
Keep track of the main points
of the meeting on a board
Speak with an open mind
Listen with an open mind

Rules For Meetings

Dont be too formal
Dont monopolize or allow
others to monopolize the
discussion
Avoid talking in vague
generalities
Accept contrary views
(Nemawashi)
Express your views when
they are fresh

Ten Tips For Leaders

During The Meeting:
At the start of the meeting, write the
scheduled ending time in big letters
Assign specific people to fill the roles of
facilitator, scribe and activity board
manager
Go over the agenda of subjects for
discussion and decision
For each action decided, confirm and
target completion dates and responsible
personnel
Set the date for the next meeting &
thank everyone

Ten Tips For Leaders

After The Meeting:
Post minutes on the Activity
Board and distribute minutes
Update the teams action plan
Report to your manager and get
his or her guidance and advice

Chapter 5 Summary
Theme, Vision, Targets, Methods,
Schedule, Roles and Assessments
Activity Boards serve as a guide to the
teams activities and accomplishments
Activity Boards should be clear and serve
as discussion points for meetings
Activity Boards should show at a glance the
teams goals, specific problems, actions,
deadlines and results

Autonomous
Maintenance
for Operators
Chapter 6
One Point Lessons

What is a One Point Lesson (OPL)?

A 5-10 minute self-study lesson
drawn up by team members
Topic should only take one
page if possible
OPLs cover a single aspect of
equipment, structure, function
or task
Reduces training costs

OPL As A Cascading Training Tool

Its not enough to pass on
information verbally
OPLs capture knowledge
from team leaders and
members
OPLs are short and
focused on a topic that is
frequently discussed
OPLs put knowledge into
simple & clear form

Purposes and Philosophy

OPLs have 3 Purposes:
To help sharpen equipmentrelated knowledge and skills
and communicate information
about specific problems
To share important information
easily when it is needed
To improve the performance of
the team

Purposes and Philosophy

The Philosophy of OPLs:
Develop and research the
lesson yourself
The company makes up their
own lesson sheets
Explain them to all team
members
Discuss OPLs openly
Improve them as needed

Types of OPLs
Basic Knowledge Lessons:
Used to fill in knowledge gaps
Ensure team members have
the knowledge the need for
daily production & TPM
activities
May focus on:
Lubrication, Inspection
Safety Aspects
5S, etc.

Types of OPLs
Examples of Problems:
Based on problems that are
reoccurring
Lessons are designed to
communicate knowledge or
skills to eliminate future
problems
Should show defect as well
as how it should be

Types of OPLs
Examples of Improvements:
Ensure successful
improvement ideas are widely
used
Illustrates what needs to be
done to prevent or correct
abnormalities
Describes the approach
Actions to be taken
Results of improvement projects

OPL Form
Should be customized for
your organizations needs
Might include 5S, AM,
Safety etc.
OPL should be posted at the
point of use
Long SOPs can be
simplified into OPLs

Tips for Writing OPLs

Be relevant based on a
common problems the
workplace is currently
facing
Dont just describe the
problem in words use
pictures, diagrams etc.
Make lessons immediately
after a problem has
occurred and teach if while
its fresh

Presenting the OPLs

Ask people questions and
after the presentation and
follow up on the topic
discussed
Repeat several times (if
needed) until the issue is
resolved

OPL Examples

OPL Examples 115-118

OPL Examples 115-118

Chapter 6 Summary
OPLs are to be used with Activity Boards
for continuous training
OPLs are 5-10 minute training modules
that can be constructed by any team
members
Should be made right after a problem has
occurred so the OPL is relevant
Present the OPL to the AM team and
encourage feedback