AUTONOMOUS MAINTENANCE
workshop
Upgrading Operator Capability with Basic Maintenance Skills.
Description
Autonomous Maintenance (Jishu Hozen) is a critical aspect of Total Productive Maintenance (TPM) that involves operators in maintaining their own equipment independently, without relying on the maintenance department. Activities within an AM program include daily inspections, lubrication, parts replacement, simple repairs, abnormality detection, and precision checks.
The primary goals of the AM program are to prevent equipment deterioration, restore equipment to its ideal state, and establish the basic conditions needed to keep equipment well-maintained. AM is one of the most important building blocks of any TPM program and plays a crucial role in reducing downtime, lowering maintenance costs, and developing a higher skilled operative and maintenance workforce.
This one-day workshop, facilitated by our JIPM-certified TPM consultant, is designed to help you kick start an Autonomous Maintenance program to support your TPM implementation. You will learn the step-by-step implementation of the AM Pillar, how to conduct TPM meetings, create one-point lessons, and set up activity boards. Additionally, you will develop the basic maintenance skills required to ensure that your AM program is successful.
Recommended Audience
This course is recommended for Managers, Engineers, Supervisors, TPM steering committee and other operational staff from production, manufacturing, engineering and maintenance.
Methodology
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Facilitated by JIPM-certified TPM Instructor
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Lectures, video presentations, group activities, discussions and Q&A
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Case studies of AM activities and implementation
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Examples and illustrations of AM practices in industries
Learning Objectives
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Understand the key concepts of TPM and Autonomous Maintenance
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Understand the six big losses that lower equipment efficiency
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Acquire knowledge on how to implement the Autonomous Maintenance activities, step by step
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Learn how to use activity boards, team meetings and one-point lessons to promote TPM goals
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Understand the critical success factors in sustaining Autonomous Maintenance activities on the shopfloor
Workshop Outline
Award of Certificate
Certificate of Attendance will be issued to participants who have attended at least 75% of the workshop
Duration
1 day
4. Implementing the Seven Steps of Autonomous Maintenance
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Step 1 - Clean & Inspect
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Step 2 - Eliminate Problem Sources & Inaccessible Areas
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Step 3 - Draw Up Cleaning & Lubricating Standards
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Step 4 - Conduct General Inspections
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Step 5 - Conduct Autonomous Inspections
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Step 6 - Standardize Through Visual Workplace Management
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Step 7 - Implement Autonomous Equipment Management
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Autonomous Maintenance and Safety
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Key Implementation Points for AM
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Role of Management
5. Measuring & Auditing Autonomous Maintenance Performance
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Performance Metrics for AM
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Three Important Reasons for Audits
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AM Audit Checklists based on the JIPM TPM Excellence Criteria
6. JIPM TPM Excellence Criteria for Autonomous Maintenance
7. How to Sustain Autonomous Maintenance
8. Summary
1. Overview of TPM
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Common Features of Workplaces with Poor TPM Practices
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Machine Failures Have Many Hidden Causes
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What is TPM?
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TPM Principles
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Why is TPM Important?
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TPM Goals
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TPM Benefits
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TPM Pillars & Activities
2. Introduction & Key Concepts of Autonomous Maintenance
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AM - Is and Is Not
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AM is a Paradigm Shift
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AM Supports a Culture Change
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AM Activities Improve Equipment Efficiency & Upgrade Operator Skills
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Accidents Occur When Unsafe Conditions Combine with Unsafe Behavior
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Characteristics of AM Programs
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Goals of AM
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Natural and Forced Deterioration
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Four Equipment-related Skills for Operators
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AM Approach
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Activities Beyond the Scope of AM
3. Key Tools for Autonomous Maintenance Team Activities
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Activity Boards
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Team Meetings
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One-Point Lessons