When preventive maintenance was developed at USA, Noppondenso was the first company introduce preventive maintenance in 1960. In implementation, operator produced goods using machines and maintenance group was dedicated to maintain the working of the machine. Because the machine more complex, the needs for more maintenance personnel was essential. So the management decided that routine maintenance would be carried out by operator. Maintenance groups only took the essential maintenance works. This was the first Autonomous Maintenance implemented the practice of maintenance.
As one of TPM pillar, autonomous maintenance promotes the development of production operators to be able to take care small maintenance tasks such as cleaning, inspecting and lubricating their equipment. Production operators are expected to involve in doing basic care and daily maintenance of their machine. Not only basic care and daily maintenance but also continuous improvement (Kaizen) become more essential in the Autonomous Maintenance implementation.
JIPM (Japan Institute of Plant Maintenance) have promote the Autonomous Maintenance in seven step. I think it is very common in the implementation of Autonomous Maintenance. These seven step can be followed as below :
All of these seven step can be divided into three big items which are :
Step 1 to 3 : Restoration and improve basic machine condition
- Step 4 to 5 : Prevention of deterioration
- Step 6 to 7 : Optimization of AM
The purpose of autonomous maintenance are to maintain basic equipment condition, to adhere the usage of equipment, by visually to inspect for external deterioration of equipment, to detect signs of abnormalities by five senses and by relatively easy machine diagnostic techniques and to enhance operating, setup, adjustment and inspection skill.
In the first step; initial cleaning, production personnel is expected to clean their machine at the same time should find abnormal in their machine. Abnormal means something is not proper that can impact the runnability, quality, performance, safety and condition of work-place.
By doing initial cleaning, production personnel will have a new experience about their machine and know more about their machine; the symptom before the equipment breakdown will be more easy to be detected and proper operation will be sustained. The production personnel will find the experience where they found the abnormal at their machine and they will start to think how to solve the abnormal and how to prevent in the future so the abnormal will not happen again and the end the machine condition will be tidy and clean. I believe no one want it dirty again. This condition will be as foundation of the relation between production personnel and machine. This relationship will be made stronger and deeper by implementing AM until the rest steps.
This relationship will bring production personnel will not let the machine down or create flaw on the final product. Slowly the operator will understand the machine language that will be sound if abnormal happen. Ownership of the production personnel about their equipment will be established. Imagine if we have a car, we will try to be more familiar about the language of the car, what will it sound if the gas is lack or what will sound if time to change the lubrication..etc. Maintenance specialist will verify the actual condition by implementing the predictive maintenance tools so it can be more clear in number.
Caring the machine is about ownership. How is your production personnel caring about their equipment? Did they find abnormal before it broke?
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