Autonomous maintenance

3 days

the present oriented towards the future
course code 3. 15

What is the course for

#1

Increasing the operational availability and useful life of the equipment

#2

Increasing people's involvement and sense of responsibility, therefore expanding your base of problem solvers

#3

Increasing people's skills

The value of a company is measured by the value and the skills of each and every one of its people. Autonomous Maintenance, one of the pillars at the heart of Lean Total Productive Maintenance and World Class Manufacturing business transformation planning, aims to increase operators’ skills and responsibilities in order to increase their involvement and participation in improving plant conditions. Only operators are able to perceive the small signals given off by machinery which, if properly read and interpreted, allow them to improve the equipment’s efficiency and extend its useful life.

Goals

  • Increasing the operational availability and useful life of equipment
  • Increasing people’s involvement and sense of responsibility, therefore expanding your base of problem solvers
  • Increasing people’s skills
  • Increasing the order and cleanliness of the equipment

Addressed to

  • Plant managers
  • Production managers
  • Maintenance managers
  • Production supervisors
  • Process engineers
  • Operators

Contents

Preliminary activities

  • How to set up an autonomous maintenance project
  • How to identify and choose a model area
  • How to select a project team
  • How to define a master plan to implement autonomous maintenance
  • How to manage the team’s specific training and what to share.
  • Which autonomous maintenance performance indicators (KPIs) to use and their link to the model area’s performance indicators.

Initial cleaning

  • Organising an initial cleaning event
  • Creating safety maps
  • Cleaning as inspection
  • How to implement the “card” system
  • Creating a management system for cleaning, inspection and lubrication.
  • How to link the evolution of autonomous maintenance to the model area’s performance
  • Creating an AM assessment system

Eliminate sources of dirt and difficult-to-access access areas

  • How to locate and map sources of dirt and difficult-to-access areas
  • Techniques for eliminating sources of dirt and difficult-to-access access areas.
  • Optimising inspection and cleaning times
  • Visual Management, first applications.

Consolidating temporary cleaning, inspection and lubrication standards

  • How to create a standardised lubrication system
  • How to initiate a process of transferring lubrication and inspection skills from maintenance operators to production operators.
  • Starting a regulation optimisation system

General machine inspection

  • How to create a general inspection system
  • How to develop a technical training system
  • Developing the skills of the machine drivers

General process inspections

  • How to create a system for inspecting processes
  • Q-points, theory, detection and their control
  • Visual management; extension
  • Identifying anomalies and understanding the causes

Introduction to process-specific improvement methods

  • How to create a system for inspecting processes
  • Q-points, theory, detection and their control
  • Visual management; extension
  • Identifying anomalies and understanding the causes

You will experience

  • Tags
  • Timetables and cleaning inspection and lubrication standards
  • OPL (One Point Lessons)
  • SOPs (Standard operating procedures for AM)
  • The cause and effect diagram (problem-solving technique)
  • The 5 Why (problem-solving technique)
  • The audit check list
  • Q-Point
  • QX and QM Matrix
  • Poka Yoke – avoid mistakes
  • ECRS – Eliminate/ Combine/ Rearrange/ Simplify

Download the in-company training catalogue