Autonomous Maintenance

(Jishu Hozen)
Training Material
Autonomous Maintenance
 Coverage of Subjects

 Aim and Importance of Autonomous Maintenance.

 Definition of Autonomous Maintenance.

 Mindset of Production and Maintenance Departments.
 Equipment Deterioration.
 Classification and Role of Maintenance Activities.
 7 Steps of Autonomous Maintenance Activities.
 7 Types of Abnormalities.
 Harmful Effects of Inadequate Cleaning.
 Coverage of Subjects

 Check Points while carrying out Autonomous Maintenance

Activities.
 Problem Identification tags.
 Implementation of Autonomous Maintenance steps 1 to 3.
 Four Steps to become an Operator Strong.
 Visual Display Stickers.
 Autonomous Maintenance Sticker and Check List.
 One point lesson.
Sorting
Systematic
Arrangement

Cleanliness

Standardization Training & Discipline

 Aim

 Develop the operators that have

proficient skill in
 Equipment
 Mechanism
 Autonomous Maintenance of his own
equipment
Methodology

Execution of 7 Steps of Autonomous Maintenance

With Whom

Team leaders & Operators

 Importance of Autonomous Maintenance !
 To Prevent Equipment Deterioration.

 To Maintain Equipment in Optimal Condition.

 To Establish Basic Equipment Condition.

 To Eliminate Equipment Failure.

 To Make Operator Equipment Competent.

 To Eliminate Quality Defects.

 To Eliminate Cost Losses.

 Autonomous Maintenance
“ Autonomous Maintenance “ is the
activities which each operators performs
– Daily Cleaning, Lubrication, Inspection,
Tightening, Parts Replacement, Repair,
Trouble Shooting, Accuracy Checks and
so forth on his own equipment, aiming at
achieving the Goal of keeping “ One’s
own equipment in Good condition by
One self “.
 The Mind set ….

Production
 Maintenance does not its Job.
 They take too long to correct the Equipment.
 This Equipment is so old no wonder it breaks
down again and again.
 We are too busy to do Vital Daily Checks.
 The Mind set ….

Maintenance
 Production do not Know how to operate.
 We get lot of repairs, see we don’t have ample to
do a real corrective action and are forced to do only
temporary job.
 We Prepare the Standards but they do not do the
checks.
 Equipment Deterioration

1.Natural Deterioration. 2.Accelerated Deterioration.

Natural Deterioration
o Life Time to be Extended.
o Corrective Maintenance.

 Prevent Errors by improving operability.

 Improve Maintainability and Repair Quality.
 Improve Safety and Reliability.
 Equipment Deterioration

Accelerated Deterioration
o Causes to be Eliminated.
o Establish Basic condition.

 Cleaning eliminates all dust and dirt.

 Lubricating keep lubricants clean and replenished.
 Tightening keep Nuts and Bolts secure.
 Emphasis is on prevention

Preventive Medicine for equipment is Preventive Maintenance

Periodic
Daily Exercises Health Check-ups Early Treatment
For Prevention For Diagnosis For Correction

Prevent Measure Repair

Deterioration Deterioration Deterioration

Daily Maintenance Periodic Inspection Preventive

-Clean To a Planned Repairs and
-Inspect Maintenance Advance
-Lubricate Schedule Replacements
-Retighten
 JH prevents “Forced Deterioration” of equipment

Natural
Deterioration
Machine Condition

Forced
Deterioration

Time Period
SEE THAT IS YOUR MACHINEDEFECTIVE ?
 Classification of Maintenance Activities

1. Activities to prevent Deterioration

By correct operation, Improvement of basic
condition and adjustments to prevent quality
defects.
2. Activities to measure Deterioration
By senses ( Touch, See, Hear and Smell ).
3. Activities to rectify Deterioration
By Improving Reliability, Maintainability of
Machines – MTBF and MTTR.
 Role of Maintenance Activities

Role of Production Department

Play Vital role in Preventing Deterioration.
Records Maintenance data for prevention of
recurrences of Problem and Poor Design.
Play role in measuring deterioration by Five
Senses.
Play role in rectifying deterioration by prompt
reporting and assisting in sporadic failure.
 Role of Maintenance Activities

Role of Maintenance Department

Play role in as a Guide and educationist and providing
help in identifying areas “ Sources of Problems” and “
Hard to Clean”.
Play role in measuring deterioration by Vibration.
Play role in rectifying deterioration by Improving
MTBF and MTTR.
Maintain MIS, Work for New Equipment design and set
up maintenance standards.
 7 JH Steps
Step 7
Autonomous Management

Step 6
Standardization

Step 5
Autonomous Inspection

Step 4
General Inspection

Step 3
Tentative Standards

Step 2
Countermeasures

Step 1
Initial Clean-up
 Concept of JH Steps implementation
Defects &
Failures
Are
The shames of
Shop-floor

Step 0 Step 1
(Preparation) Step 2 Step 4
Change Step 6
Step 3 Step 5
Thinking Step 7
Defects & Zero
Change Change Change
Motivate Failures Defects &
Equipment People Workplace
reduced Failures
Change
Activities

Positive actions
Why forced Clean to inspect Restoration TPM Circles
For
Deterioration? & inspect to find Improvements Solving
Maintenance
Why JH minor defects Then the joy of Problems
Improvement &
Necessary? & repair achievement Bottom-up
Management

Teach ability
Understanding
to find minor
Safety needs
defects & guide
During
to do
JH Step 1
improvements
 7 Steps of Autonomous Maintenance

Step No.: 1
Initial Clean-up
All-around clean-up of Dust and Dirt.
Centering of Equipment properly.
Implementation of Lubrication activities.
Machine parts Adjustment.
Discovery and Repair of Abnormalities /
Malfunctions in Equipment.
 HEY !
CLEANING
IS WHAT IS THE
INSPECTION
OIL FUNNEL
DOING HERE

CLEANING IS INSPECTION
MINOR DEFECTS ARE NOTICED
DURING MACHINE CLEANING
JH Step 1 : Initial Clean-up

Initial Clean-up

Cleaning + Inspection

Cleaning is Inspection

Cleaning with meaning

Reveal latent defects

 7 types of Abnormalities

o Minor Flaws.
o Unfulfilled basic Conditions.
o Inaccessible Places.
o Contamination Sources.
o Quality Defect Sources.
o Unnecessary and Non-Urgent Items.
o Unsafe Places.
 1. Minor Flaws
 Contamination - Dust, Dirt, Powder, Oil, Grease, Rust and
Paint.
 Damage - Cracking, Crushing, Deformation, Chipping and
Bending.
 Play - Shaking, Falling out, Tilting, Eccentricity, Wear,
Distortion and Corrosion.
 Slackness - Belts and Chains.
 Abnormal Phenomenon - Unusual Noise, Over Heating,
Vibration, Strange Smells, Discoloration, Incorrect Pressure or
Current.
 Adhesion - Blocking, Hardening, Accumulation of Debris,
Peeling and Malfunction.
 2. Unfulfilled Basic conditions

 Lubrication – Insufficient, Dirty, Unidentified, Unsuitable

and Leaking.
 Lubrication Supply – Dirty, damaged or deformed
lubricant inlets, Faulty Lubricant Pipes.
 Oil Level Gauges – Dirty, Damaged, Leaking, No
indication of Correct Level.
 Tightening – Nuts and Bolts Slackness, Missing, Cross-
Threaded, Too Long, Crushed, Corroded, Unsuitable washers,
Wing Nuts on Backward.
 3. Inaccessible Places
 Cleaning – Machine Construction, Covers, Layout, Footholds
and Space.
 Checking – Construction, Covers, Layout, Footholds,
Instrument Position and Orientation, Operating Range and Display.
 Lubricating – Position of Lubricant Inlet, Construction, Height,
Footholds, Lubricant Outlets and space.
 Tightening – Covers, Construction, Layout Size, Space.
 Operation – Machine Layout Position of Valves, Switches and
Leavers and Footholds.
 Adjustment – Position of Pressure Gauges, Gauges,
Thermometers, Flow Meters, Moisture Gauges, Vacuum Gauges
etc….
 4. Contamination Sources
 Product – Leaks, Spills, Spurts, scattering, Overflow.
 Raw Materials – Leaks, Spills, Spurts, scattering, Overflow.
 Lubricants – Leaking, Spills, Sweeping oils, Hydraulic Fluids,
Fuel Oils etc.….
 Gases – Leaking Compressed air, Gases, Steam, Vapours,
Exhaust fumes,etc..
 Liquids – Leaking water, Hot, Old, Half Finished Products,
Waste water, Leaking Supply lines etc.
 Scrap – Flashes, Cuttings, Packaging Materials and non
conforming Products.
 Others – Contaminants by people and Forklifts, Infiltration
through cracked walls, broken windows etc.
 5. Quality Defect Sources
 Foreign Matter – Dust, Rust, Powder, Chips, Moisture,
Wire Scraps, Wood Pieces, Paper Pieces, Stones etc….
 Shock – Dropping, Jolting, Collision, Vibration etc…
 Moisture – Too Little or Too Much, Infiltration.
 Gain Size – Abnormalities in Screens, Compressed air
separators, Centrifugal Separators.
 Concentration – Inadequate warming,
Heating,Compounding, Mixing, Evaporation, Stirring etc…
 Viscosity – Inadequate warming, Heating, Compounding,
Mixing, Evaporation, Stirring etc
 6. Unnecessary and Non-urgent Item
 Machinery – Pumps, Fans, Compressors, Columns, tanks etc….
 Piping Equipment– Pipes, Hoses, Ducts, Valves, Dampers
etc….
 Measuring Instruments– Temperatures, Pressure Gauges,
Vacuum Gauges, Ammeters etc…
 Electrical Equipment – Wiring, Piping, Power Leads,
Switches, Plugs etc…
 Jigs & Tools – General Tools, Cutting Tools, Jigs, Moulds, Dies,
Frames etc…
 Spare Parts – Standby Equipment, Spares, Permanent Stocks,
Auxiliary Materials etc…
 Makeshift Repairs – Tape, String, Wire, Metal Plates etc…
 7. Unsafe Places
 Floors – Unevenness, Cracked, Holes, Projections, Peeling,
Wear of Steel Chucker Plates, Slipping etc…
 Steps– Too Steep, Irregular, Slipping, Missing Handrails, etc…
 Lights– Dim, Out of Position, Dirty or Broken Covers, No
Explosion Proofing etc…
 Rotating Machinery – Displaced, Fallen oil or Broken Covers,
Not Safe for Emergency, Missing Emergency Stop Devices…
 Lifting Devices – Wires, Hooks, Brakes and other parts of
Cranes and Hoists etc…
 Others – Special Substances, Solvents, Toxic Gases, Insulating
Materials, Danger Signs, Protective Clothing etc…
 CLEANING RESULTS

Before After
 Harmful effects of inadequate cleaning
 Failure – Dirt and Foreign matter penetrates rotating parts, Sliding
Parts, Pneumatic and Hydraulic Systems, Electrical Control Systems
and Sensors etc., causing loss of Precision, Malfunction and failure as
a result of wear, Blockage, Frictional Resistance, Electrical faults etc..
 Quality Defects – Quality Defects are Caused either directly by
contamination of the product with foreign matter or Indirectly as a
result of Equipment malfunction.
 Accelerated Deterioration – Accelerated dust and Grime make it
difficult to find and rectify Cracks, Excessive Play, Insufficient
Lubricants and other Disorders resulting in Accelerated Deterioration.
 Speed Losses – Dust and Dirt increase Wear and Frictional
Resistance causing speed losses such as idling and under
performance.
INTRODUCTION OF PCB CLEANING STANDARDS

Problem : Prior to TPM implementation,

the PCB used to fail and get replaced
once in a month.
Cause & Analysis : During the
operation, fine metal dust entering the
control panel and carbon dust generated
within the panel resulted in the short
circuiting of the PCB’s.
Solution: Introduce periodic PCB
cleaning standards .
Result : MTBF for PCB breakdown has
increased from one Month to 2 Years.(No
breakdown since the introduction of PCB
cleaning standards).
 Concept of JH Steps implementation

My Management

My Work I improve

JH Step 7
My Machine I control

JH Step 6
I maintain

JH Step 4
I operate

Before TPM
 7 Steps of Autonomous Maintenance

Step No.: 2
Measures against Sourcess
Prevent causes of Dust, Dirt and Scattering.
Improve places which are difficult to clean and
lubricate.
Reduce the time required for clean-up and
Lubrication.
FIND THE ROOT CAUSE OF OIL LEAKAGE
AND ELIMINATE .
OIL IN THE FLOOR !!!!!!
FIND THE ROOT CAUSE OF OIL LEAKAGE
AND ELIMINATE .

OIL PIPE LINE

DEFECTIVE MACHINE PRODUCES
DEFECTIVE PRODUCTS
Clean and clear all the
scrap collected around the or else.
machinery everyday
 ELIMINATION OF DESIGN WEAK POINTS

Elimination of camshaft
Belt cutoff problem
By changing the
material
Composition

Camshaft belt used to cut off

twice a month resulting in
downtime of 30mins on each
occasion

After changing the belt material from 100% Nylon to 90%

Nylon + 10% Rubber, the above breakdown has not
occurred during the last 28 months.
ELIMINATION OF CLEANING DIFFICULTIES

BEFORE TPM
At rear side of the machine, 10
screws have to be removed for
opening the door which took 7
Mins.

AFTER TPM
INJ.MOULDING MACHINE DL250
Door hinge is provided for easy
opening which takes 5 Sec.
 Checkpoints for Nuts and Bolts
 Slight Defects – Loose Nuts & Bolts, Missing Nuts and Bolts.
 Bolt Length – All Bolts should protrude from nuts by 2-3 threads.
 Washers –
1. Are flat washers used on long holes ?
2. Are tapered washers used on angle bars & Channels ?
3. Are Spring washers used for parts subjected to Vibration ?
4. Are identical washers used in identical parts ?
 Fixing of Nuts and Bolts -
1. Are bolts inserted from below ?
2. Are they visible from outside ?
3. Are devices such as Limit Switches fastened at least by 2 Bolts ?
4. Are Wing Nut direction Clockwise ?
 Checkpoints for Lubrication
 Lubricant Storage –
1. Are Lubricant stores always kept clean, Tidy and 5S principles
applied ?
2. Are Lubricant Containers always capped ?
3. Are Lubricant Type clearly indicated and is proper stock control
practiced ?
 Lubricant Inlets –
1. Are Grease Nipples, Speed reducer lubricant ports and other lubricant
inlets always kept clean ?
2. Are Lubricant inlet dust proofed ?
3. Are Lubricant inlets labeled with correct type and quantity of Lub ?
 Checkpoints for Lubrication
 Oil Level Gauges –
1. Are Oil level Gauges always kept clean and Oil levels easy to check ?
2. Is the correct oil level clearly marked ?
3. Is Equipment free of oil leaks and Oil pipes and Breathers
unobstructed ?
 Auto Lub Devices –
1. Are Auto Lubricating devices operating correctly and supplying
correct quantity of lubricants ?
 Lubricating Condition –
1. Are Rotating, Sliding Parts and transmission well lubricated ?
2. Are the Surroundings free of contamination by excess lubricant ?
 Checkpoints for Transmission System

V Belts and Pulleys

1. Are any belt Cracked, Swollen, Worn-out or contaminate by Lub ?
2. Are any belt Twisted or Missing ?
3. Are any belt Stretched or Slack ?
4. Are Multiple belts under uniform tension and all of the same Type ?
5. Are top surfaces of Belts protruding above the pulley Rims ?
6. Are the bottoms any pulley groves shiny ( Indicating a worn belt or
pulley ) ?
7. Are Pulleys Correctly Aligned ?
 Checkpoints for Nuts and Bolts
 Slight Defects – Loose Nuts & Bolts, Missing Nuts and Bolts.
 Bolt Length – All Bolts should protrude from nuts by 2-3 threads.
 Washers –
1. Are flat washers used on long holes ?
2. Are tapered washers used on angle bars & Channels ?
3. Are Spring washers used for parts subjected to Vibration ?
4. Are identical washers used in identical parts ?
 Fixing of Nuts and Bolts -
1. Are bolts inserted from below ?
2. Are they visible from outside ?
3. Are devices such as Limit Switches fastened at least by 2 Bolts ?
4. Are Wing Nut direction Clockwise ?
 Checkpoints for Lubrication
 Lubricant Storage –
1. Are Lubricant stores always kept clean, Tidy and 5S principles
applied ?
2. Are Lubricant Containers always capped ?
3. Are Lubricant Type clearly indicated and is proper stock control
practiced ?
 Lubricant Inlets –
1. Are Grease Nipples, Speed reducer lubricant ports and other lubricant
inlets always kept clean ?
2. Are Lubricant inlet dust proofed ?
3. Are Lubricant inlets labeled with correct type and quantity of Lub ?
 Checkpoints for Lubrication
 Oil Level Gauges –
1. Are Oil level Gauges always kept clean and Oil levels easy to check ?
2. Is the correct oil level clearly marked ?
3. Is Equipment free of oil leaks and Oil pipes and Breathers
unobstructed ?
 Auto Lub Devices –
1. Are Auto Lubricating devices operating correctly and supplying
correct quantity of lubricants ?
 Lubricating Condition –
1. Are Rotating, Sliding Parts and transmission well lubricated ?
2. Are the Surroundings free of contamination by excess lubricant ?
 Checkpoints for Transmission System
Roller Chains
1. Are any chains stretched indicating worn-out pins or bushings ?
2. Are any sprocket teeth worn-out, Missing or Damaged ?
3. Is Lubrication between Pins and Bushings sufficient ?
4. Are Sprockets correctly aligned ?
Shafts, Bearings and Couplings
1. Is there any Overheating, Vibration, Abnormal noise due to Excessive
Play or Lack of Greasing ?
2. Are any Keys or Set bolts loose or missing ?
3. Are any Couplings misaligned or Wobbling ?
4. Are any Seals worn-out ?
 Checkpoints for Transmission System

Gears
1. Are Gears rightly lubricated with proper amount of Lubricant ?
2. Are any teeth Missing, Damaged, worn-out or jammed ?
3. Is there any Unusual noise or Vibration ?
 Checkpoints for Hydraulic System

Hydraulic Check Points

1. Is there correct quantity and level indicated for fluid in the reservoir ?
2. Is fluid of correct Temperature and its Minimum and Maximum
Temperature is indicated ?
3. Is Fluid cloudy ( Indicating air entrapment ) ?
4. Are all Fluid inlets and Strainers clean ?
5. Are any Suction filters blocked ?
6. Are any Fluid Reservoir breather filters blocked ?
7. Are Fluid Pumps operating without any unusual noise or vibration ?
8. Are Hydraulic Pressure correct and Operating ranges displayed ?
 Checkpoints for Hydraulic System
Heat Exchangers
1. Is any fluid or water leaking from fluid coolers or pipes ?
2. Are temperature differences between fluid and water inlets and outlets
are correct ?
3. Are any Tubes blocked ?

Hydraulic Equipment
1. Are there any fluid leaks ?
2. Are Hydraulic systems properly fastened ?
3. Are Hydraulic devices operating correctly without speed loss or
breathing ?
4. Are Hydraulic pressure correct and all Gauges working ?
 Checkpoints for Hydraulic System

Piping and Wiring

1. Are all pipes and hoses fastened tightly ?
2. Are there any fluid leaks ?
3. Are any hoses cracked or damaged ?
4. Are all Valves operating correctly ?
5. Is it easy to see whether valves are open or closed ?
6. Are any Pipes / Valves unnecessary ?
 Checkpoints for Pneumatic System

FRLs
1. Are FRLs clean ? Is it easy to see inside of them ? Are they fitted right
away around ?
2. Is there sufficient oil, and are the drains are clear ?
3. Is the oil dip rate correct ? ( Approx 1 drop for every 10 Stroke )
4. Are the FRLs installed not more than 3 m from the equipment ?
5. Are the pressure adjusted to the correct value and operating ranges are
clearly indicated ?
 Checkpoints for Pneumatic System

Pneumatic Equipment
1. Is compressed air leaking from pneumatic cylinders or solenoids ?
2. Are all pneumatic cylinders and solenoid valves firmly fastened ?
3. Are any pistons dirty, Worn, damaged ?
4. Are the speed controllers installed right away around ?
5. Is there any abnormal sound or overheating of solenoid valves and are
any lead wires chafed or trailing ?
 Checkpoints for Pneumatic System

Piping and Hoses

1. Are there any places in Pneumatic pipes or hoses where fluid is liable
to collect ?
2. Are all hoses and pipes clipped firmly in place ?
3. Are any hoses cracked, damaged ?
4. Are there any air leaks ?
5. Are valves operating correctly and open and close position known ?
 Checkpoints for Electrical
Control Panels
1. Are the interiors of Distribution boards, Switch boards and control
panels kept clean, tidy and well organized by the application of 5S
activities ?
2. Have any objects or Flammable materials been left inside ?
3. Is the wiring inside control panels in good condition ? Are any wires
coiled or trailing ?
4. Are all Ammeters and Voltmeters operating correctly ?
5. Are any Switches, Bulbs broken ? DO all Switches work correctly ?
6. Are Panel doors in Good condition ? Do they open & Close easily ?
4. Are there any unused holes ? Are control panels water and dust proof ?
 Checkpoints for Electrical

Electrical Equipment
1. Are all motors free of Overheating, Vibration, Unusual noise and
Smell ?
2. Are all motor cooling fans and fins are clean ?
3. Are any bolt loose ?
4. Are pedestals free of cracks and damages ?
 Checkpoints for Electrical
Sensors
1. Are all manual switches clean and free of damages and excessive
play ?
2. Are all switches installed in the correct position ?
3. Are the interiors of limit switches is clean ? Are any wires coiled or
trailing ?
4. Are any limit switch dogs worn-out, deformed or of the wrong shape ?
5. Are all Photoelectric switches and proximity switches clean and free
of excessive play ?
6. Are any sensors out of position ? Are correct positions clearly
indicated ?
7. Are all lead wires un-chafed and is solution intact at entry points ?
 Checkpoints for Electrical

Switches
1. Are all switches installed in the correct position ?
2. Are all manual switches clean and free of damages and excessive
play ?
3. Are emergency stop switches installed in appropriate location and are
they in good working condition ?
 Checkpoints for Electrical

Piping and Wiring

1. Are any pipes, wires, power leads loose or unsecured ?
2. Are any ground wires damaged or disconnected ?
3. Are any pipes damaged or corroded ? Are there any bare wires or
wires with damaged insulation ?
4. Are any wires coiled on the floor or dangling overhead ?
 7 Steps of Autonomous Maintenance

Step No.: 3
Formulation of Cleaning, Lubrication,
Inspection and Tightening standards
Formulate behavioral standards, so that it is possible
to steadily sustain clean-up, Lubrication, Inspection,
Tightening and Machine parts adjustment in a short
period.
ELIMINATION OF MANUAL LUBRICATION

BEFORE TPM

INJ. MOULDING M/C ST50

Lubrication was done manually

AFTER TPM

INJ. MOULDING M/C ST50

Centralized lubrication system
was implemented to avoid manual
lubrication.
 STORAGE
AREA

5S CREATES
PLEASANT
WORKPLACE

5S IMPROVES WORKING ENVIRONMENT

 7 Steps of Autonomous Maintenance

Step No.: 4
Overall Inspection
Training in check-up skills through check-up
manuals.
Exposure and restoration of minor equipment
defects through overall check-ups.
 7 Steps of Autonomous Maintenance

Step No.: 5
Autonomous Inspection (Check-up)
Formulation and Implementation of Autonomous
Check-up sheets.
Air Conditioner Chiller Plant
 7 Steps of Autonomous Maintenance

Step No.: 6
Standardization (Orderliness and Tidiness)
Standardize various types of on the job management
items and devise complete systematization of up-keep
management.
Standards for Clean-up, Check-ups, Lubrication,
Tightening and Physical distribution in the workplace.
Standardization of Data records, Die Management,
Jigs and Tools.
 Color Keyed Systems
Color keyed systems for parts:

• Defect free
• Rework
• Scrap

Color keyed systems for machine lubricants:

• Oils
• Grease
• Coolant
Electrical Switch panel
 7 Steps of Autonomous Maintenance

Step No.: 7
All-out Autonomous Management
Development of Corporate Policies and Goals.
Making improvement activities routine.
Steadily record MTBF analysis.
Carry out equipment improvements.
I take care of my
own Equipment

Clean, Lubricate,
Inspect and Tight Daily.
Replace Parts and Make
Repairs.
Detect Abnormalities
Early.
Check Precision.
 INSPECTION
ZERO AND
MINOR SERVICING
DEFECTS BECOME
EASIER

EACH PERSON
TAKES CARE OF
HIS
RESPONSIBILITIES

PREVENTION A FEELING

OF OF ATTACHMENT
ACCELERATED IS FOSTERED
DEGRATION

BENEFITS OF OWNERSHIP
Implementation of Autonomous Maintenance

Step No.: 1
Initial Clean-up
Cleaning is inspection.
Use 5 Senses for cleaning.
Find out 7 types of Abnormalities.
Put Tags on Abnormalities.
Prepare list of unfulfilled basic conditions.
Implementation of Autonomous Maintenance

Step No.: 1
Initial Clean-up
Make the list of
Hard to Clean.
Hard to Lubricate.
Hard to Tighten.
Hard to Inspect.
Hard to Adjust.
Implementation of Autonomous Maintenance

Step No.: 1
Initial Clean-up
Record cleaning time.
Carryout Audit on First Step.
Meeting after the daily activities.
Refer to the old History records.
 Sl.No.

Exact

Location of
Abnormality
Description of

Dirt
Leak
Splash /
Spillage
Loose
Missing
Wear
Broken
Chipping
Bent
Holes / Gap
Abnormality

Abnormal
Noise
Excessive
Heat
Vibration
Abnormality Tag Matrix

Discoloration
Abnormal
Movement

Breakdowns

Quality
Rejects
Cost
Increase
Power
Abnormality Leads to

increase
 List of Abnormalities in the Equipment

Equipment Name : Asset No.:

Why is it Abnormality ?
Sl. Date of Abnormality Why did it become so ? Contents of the Planned Date of
Detector ( What will happen if it is Executor
No. Detection Item ( What is the Cause ? ) Countermeasures. date Completion
left as it is ? )
Implementation of Autonomous Maintenance

Step No.: 2
Countermeasures against Sources of
Contamination and Hard to do CLITA
Countermeasures against Source's of Contamination.
Make Approach easy for CLITA.
Make easy to do CLITA.
Shorten Cleaning, Lubricating, Inspecting and Tightening Time.
Adopts concepts of Localized Guards.
Ranking the priority places for Daily Cleaning.
Assembling with Easy access to Visual alarm that
white gloves. tools indicates problems.
Implementation of Autonomous Maintenance

Step No.: 3
Prepare Tentative Standards
Standards for Cleaning, Lubricating, Inspecting and
Tightening.
Standards are made by operators themselves with guidance
by Maintenance.
Standards are made by using 5W 1H.
Standards should be easily understood by everyone.
Introduce extensive Visual Controls.
Four Steps to become an Operator Strong on
Equipment and Autonomous Maintenance

 Step 1 : Familiarize with the concept of Equipment

Maintenance and Improvement and with how to put the idea
in to practical realization.
 Step 2 : Study the mechanism and functions of Equipment
and Machines.
 Learn how to operate the Equipment with the required
Accuracy and how to evaluate the product quality.
 Master how to repair the Equipment.
 Visual Display Stickers
ITEM DESCRIPTION GUIDELINES FOR PASTING STICKERS

C1
Cleaning To Paste on the parts which are all to be cleaned in
(Right & Left) the Machines / Equipments / Lines.

C1
Base Colour
of oil

To Paste on the parts which are all to be lubricated in

the Machines / Equipments / Lines.
Lubrication Note : Refer colour coding details for knowing the
colour of oil.

Particular
colour of oil
 Colour Coding details of Lubricants
BASE
SL. NO. DESCRIPTION OF OIL UNIT COLOUR
COLOUR

1 LUBRICATION OIL
YELLOW
a. PERFECTO – 32 YELLOW

b. ALPHA ZN 220 LIGHT BLUE LIGHTBLUE

c. EP – 150 YELLOW GREY

d. HYSPIN – 15 GREEN GREY

e. ACTRA NO. – 2 RED

GREEN
f. VELOCITE NO. – 3 BROWN

2 HYDRAULIC OIL
RED
a. PERFECTO – 68 YELLOW

b. HLP – 68 RED LIGHT BLUE BROWN

c. DTE – 25 GREY
DARK BLUE
3 CUTTING OIL

a. SUPERCUT – 171 YELLOW

ORANGE
b. RUSTLICK EDM 30 BLUE LIGHT BLUE

c. HONILO – 981 GREY

LIGHT GREEN
d. SOLUCUT – ALS GREEN
Colour Coding details of Lubricants
BASE
SL. NO. DESCRIPTION OF OIL UNIT COLOUR
COLOUR

4 COOLANT

a. WS 500 NR YELLOW
b. RUSTLICK WS 500 NR ORANGE LIGHT GREEN
c. ULTRACUT – 380 GREY
d. SUPEREDGE NO. – 7 GREEN

5 QUENCHING / COOLING OIL

a. ILO QUENCH NO. – 1 GREY YELLOW
6 LUBRICATION – GREASE
a. AP3 YELLOW

b. EP1 BROWN LIGHT BLUE

c. EP2 GREY
7 DIELECTRIC OIL
a. RUSTLIC EDM – 30 GREEN YELLOW

b. VITOL – KS LIGHT BLUE

 Visual Display Stickers
ITEM DESCRIPTION GUIDELINES FOR PASTING STICKERS

To Paste on the parts where problems can be noticed

Inspection -
by Smell.
Nose Example : Life of Coolant & Cutting oil.

To Paste on the parts where monitoring of process /

Inspection - conditions can be controlled by eye.
Eye Example : Level of oil in FRL unit / Where Visual
inspection is carried out.

To Paste on the parts where monitoring of problems /

Inspection - conditions can be felt by hand.
Hand Example : Heat Level of bearing surfaces / Surface
Smoothness level.

To Paste on the parts where problems can be heard.

Inspection -
Example : Noise level of rotating & sliding parts /
Ear Wherever Unsual / abnormal sound.
 Visual Display Stickers
ITEM DESCRIPTION GUIDELINES FOR PASTING STICKERS

T1
Tightening To paste on the parts which are all to be tightened in
(Right & Left) the Machines / Equipments / Lines.

T1

MINIMUM
Level
To Paste on the parts where oil / water level are to be
Minimum indicated in the Machines / Equipments / Lines.
(Right & Left)

MINIMUM
 Visual Display Stickers
ITEM DESCRIPTION GUIDELINES FOR PASTING STICKERS

MAXIMUM
Level
To paste on the parts where oil / water level are to be
Maximum indicated in the Machines / Equipments / Lines.
(Right & Left)

MAXIMUM

To Paste on the Machines / Equipments / Lines / Parts /

Unsafe Zone Areas where some safety alert is required.
Example : Ram up and down movement in presses.

Movement To Paste on the parts where Up and Down / To and Fro

motions are observed and to be indicated in the
Indication Machines / Equipments / Lines.
Sticker Example : Ram up and down movement in presses.
 Visual Display Stickers
ITEM DESCRIPTION GUIDE LINES FOR PASTING STICKERS

PMD To Paste on the parts where maintenance of Machines

ONLY Maintenance / Equipments / Lines are to be done by PMD only.
By PMD Only Example : Critical alignment / setting of machine
parts.

To Paste on the parts where monitoring / setting of

process parameters of Machines / Equipments / Lines
USER Maintenance are to be done by user only.
By User Only Example : Setting and monitoring of furnace
temperatures in the machine

INLET

Flow Inlet To Paste on the parts where Air/oil/water flow are to

( Right & Left ) be indicated in the Machines / Equipments / Lines.

INLET
 Visual Display Stickers
ITEM DESCRIPTION GUIDE LINES FOR PASTING STICKERS

OUTLET

Flow Outlet To Paste on the parts where Air/oil/water flow are to

( Right & Left ) be indicated in the Machines / Equipments / Lines.

OUTLET

Direction Of
Rotation -
Clockwise
To Paste on the parts where direction of rotation are to
be indicated in the Machines / Equipments / Lines.
Example : Direction of rotation of motor.

Direction Of
Rotation -
AntiClockwise
 Visual Display Stickers
SOLENOID VALVE DETAILS OIL FILLING DETAIL
Specification : Name of the Oil :

Model No. : Colour code of oil

Medium of Flow : Date Of Filling :

Operating pressure : Next due of Filling :

Solenoid Coil Voltage : Frequency of Filling :

CONTROL PANEL DETAILS HYDRAULIC CYLINDER DETAILS

Main Voltage :
Specification :
Control Voltage :
Model No. :
OLR Setting Range :
Medium of Flow :
OLR Setting Range :

OLR Setting Range : Operating pressure :

 Visual Display Stickers
AIR PRESSURE PNEUMATIC CYLINDER DETAILS
Main Line Pressure : Specification :

Machine Line Pressure : Model No. :

Machine setting Pressure Medium of Flow :

Operating pressure :

PRESSURE GAUGE
Specification :

Model No. : CAPACITY

Medium of Flow :

Operating pressure :

BELT DETAILS CHAIN DETAILS

Specification : Specification :
 One Point Lesson
 These lessons are developed to increase basic knowledge
and skill improvement to reduce breakdowns and defect due to
poor knowledge and skill.

One point lessons to be prepared

• Relating to equipment Abnormalities, Safety, Breakdown
Repeated Mistakes, Mistakes areas which lead to customer
complaints and Quality problem detected during trouble-
shooting.
• By Team Leaders, Maintenance Staff and Quality Staff.
• as Do’s and Don’ts.
Points to be referred / considered for preparing Cleaning,
Lubrication, Inspection and Tightening Standards.
Machine Manuals.
Experience of Maintenance & Production Staff and Operators.
Maintenance Breakdown Records.
Manufacturing Engineering Inputs regarding Machine Design /
Process Design.
Asking so many questions for the points - Why & How ?
Easily understood by everyone.
Introducing extensive Visual Controls.
Standards for Cleaning, Lubrication, Inspection and Tightening to
be prepared separately (In Separate Sheets).
Updating standards for Every Six / Twelve Months.
Points to be covered for preparing training material on
Know your Machine Concept
Machine Specifications / capacity.
Mechanism / Operation of the Machine.
Schematic diagram of Pneumatic, Hydraulic Lines & Electrical
Circuits.
Belt and Chain details.
Do’s and Don’ts.
Safety Aspects.
Trouble shooting.
Preventive / Predictive Maintenance Check List.
Daily, Weekly, Fortnightly, Monthly, Quarterly, Half Yearly and
Yearly Maintenance Schedule.
Thank you