自主维护保养教程推行全员参与自主维护保养的程序及推行思路

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1、Autonomous Maintenance Learning Objective understand the Autonomous Maintenance performance expectations for:-Program Implementation-Progress Measurement-Stages and StepsEffectiveness of Line Team Meetings Our line teams meet once a month to review performance At these meetings,operators often raise

2、 issues The meetings could be more effective We need to formalize the agenda and process to capture,prioritize and address problems in accordance with business needsTopic 2:Autonomous Maintenance Implementation Implementation Plan Performance Expectation Identify natural work teams(natural team&equi

3、pment-based team)Define roles and responsibilities Identify line sponsors(work area Team leader/S&C),line owners(operator with enough knowledge and leadership skills),and support resources(S&C)Conduct small group meetings(Twice a month)Create a project plan(An action plan for each natural team throu

4、gh 7 steps)004-1.A 3-year implementation plan outlining a site-wide approach should be in place to help the plant progress through Autonomous Maintenance activities.SGM is used to complete any of the following activities:l Review and analyze equipment losses.l Review status of action items on Equipm

5、ent Problems and Defects List.l Conduct root cause analysis on a specific problem and develop a recommended action plan.l Conduct training on a new topic or reinforce existing programs(e.g.,equipment,new job responsibility,5S&Visual Workplace,Safety,Quality).l Review and refresh SOPs.l Capture impro

6、vement suggestions.l Identify issues that should be elevated as maintenance requests.l Review Standard Work Instructions(PPMs,One Point Lessons,etc.).Problem Tags Performance Expectation Shift,date,individual who found problem Location,System,Equipment,Part ID Problem type Operation type Possible im

7、pact Possible corrective action Root cause004-2.Problem tags or equivalent means should be used to visually identify problems.Prioritizing Corrective Actions Performance Expectations Helps teams identify and act on equipment problems Groups problems and defects(Defective Areas,Questions,Sources of C

8、ontamination and Inaccessible Areas)Should be completed and updated for each piece of equipment004-3.Corrective actions should be prioritized based on business impact and tracked to closure using an Equipment Problems and Defects List at each step.Topic 2:Review Develop a 3 year plan Identify natura

9、l work teams Identify roles and responsibilities for each work team Identify sponsors,leaders and support resources Distribute and train on:-Problem Tags-Equipment Problems and Defects ListDrive Continuous Improvement&QualityTopic 3:Autonomous Maintenance Stages and StepsStep 3 Standardize cleaning,

10、inspection and lubrication proceduresStep 2 Eliminate contaminant sources and inaccessible areasStep 5 Operators inspect,clean,lubricate and conduct basic maintenanceEstablish Equipment Basic ConditionStep 7 Operators participate in continuous improvement activitiesPerform Daily Inspection&Basic Mai

11、ntenanceStep 6 Operators are responsible for some aspects of the physical organization and management of the workplaceStep 4 Train operators to conduct daily inspection and basic maintenanceStep 1 Complete initial deep cleaningStage3Stage2Stage1Stage 1:Establish Basic Equipment ConditionStep 3 Stand

12、ardize cleaning,inspection and lubrication proceduresStep 2 Eliminate contaminant sources and inaccessible areasStep 5 Operators inspect,clean,lubricate and conduct basic maintenanceEstablish Equipment Basic ConditionStep 7 Operators participate in continuous improvement activitiesDrive Continuous I

13、mprovement&QualityPerform Daily Inspection&Basic MaintenanceStep 6 Operators are responsible for some aspects of the physical organization and management of the workplaceStep 4 Train operators to conduct daily inspection and basic maintenanceStep 1 Complete initial deep cleaningStage3Stage2Stage1Ste

14、p 1:Initial Deep Cleaning Performance Expectation Training is the first step Allows for close inspection of the equipment and its parts Can quickly distinguish abnormal operation Understand business impact004-5.Complete initial deep cleaning(Step 1)Step 1:Initial Deep Cleaning Performance Expectatio

15、n,continued Problem Identification-Form teams for specific equipment-Ensure that the team understands cleaning is inspection,inspection leads to defect detection,and detection leads to correction of defects-Follow safety rules-Use the Equipment Problems and Defects List and Problem Tags004-5.Complet

16、e initial deep cleaning(Step 1)Step 1:Initial Deep Cleaning Performance Expectation,continued Problem Resolution-Prioritize opportunities-Address questions promptly-Update the Equipment Problems and Defects List Equipment Condition(Initial Cleaning)-Conduct for all equipment-Inspect for missing or l

17、oose parts or components004-5.Complete initial deep cleaning(Step 1)Step 2:Eliminate Contaminant Sources Performance Expectation Identify and eliminate sources of contamination Identify and eliminate inaccessible areas Prioritize corrective actions based on business impact004-6.Eliminate contaminant

18、 sources and inaccessible areas(Step 2)Step 3:Standardize Procedures Performance Expectation Design Standard Work Instructions(SWIs)for cleaning,inspection and lubrication Use SOPs,One Point Lessons and Process Picture Maps(PPMs)Use visual aids to communicate procedures004-7.Standardize cleaning,ins

19、pection,and lubrication procedures using Standard Operating Procedures and Standard Work Instructions(e.g.,One Point Lessons,PPMs)(Step 3)Stage 2:Daily Inspections and Basic MaintenanceStep 3 Standardize cleaning,inspection and lubrication proceduresStep 2 Eliminate contaminant sources and inaccessi

20、ble areasStep 5 Operators inspect,clean,lubricate and conduct basic maintenanceEstablish Equipment Basic ConditionStep 7 Operators participate in continuous improvement activitiesDrive Continuous Improvement&QualityPerform Daily Inspection&Basic MaintenanceStep 6 Operators are responsible for some a

21、spects of the physical organization and management of the workplaceStep 4 Train operators to conduct daily inspection and basic maintenanceStep 1 Complete initial deep cleaningStage3Stage2Stage1Step 4:Daily Inspection and Basic Maintenance Performance Expectation Operators should understand how the

22、equipment functions-Basic lubrication-Machine elements(fasteners)-Pneumatics-Hydraulics-Electrical systems-Power transmission drives Train operators in basic maintenance004-8.Operators are trained to conduct Daily Inspection and Basic Maintenance(Step 4)Step 5:Operator AccountabilityPerformance Expe

23、ctation Select maintenance tasks should be moved from maintenance to operations Compare tasks completed by operators and mechanics Agree to those that can be moved Develop SWIs(Standard Work Instruction)004-9.Operators have accountability to clean,inspect and lubricate,and conduct basic maintenance

24、on all equipment in accordance with established SOPs and SWIs(Step 5)Stage 3:Drive Continuous Improvement and QualityStep 3 Standardize cleaning,inspection and lubrication proceduresStep 2 Eliminate contaminant sources and inaccessible areasStep 5 Operators inspect,clean,lubricate and conduct basic

25、maintenanceEstablish Equipment Basic ConditionStep 7 Operators participate in continuous improvement activitiesDrive Continuous Improvement&QualityPerform Daily Inspection&Basic MaintenanceStep 6 Operators are responsible for some aspects of the physical organization and management of the workplaceS

26、tep 4 Train operators to conduct daily inspection and basic maintenanceStep 1 Complete initial deep cleaningStage3Stage2Stage1Step 6:Operator OwnershipPerformance Expectation Train operators Develop SWIs Budget time Conduct formal meetings New responsibilities-Spare Parts Management(nuts,bolts,“o”ri

27、ngs,etc.)-Changeover Execution and Improvement-5S and Visual Workplace-Maintain Standard Procedures-On-line Quality-Maintenance Notifications004-10.Operators take ownership of additional responsibilities relating to their work areas,not limited to but including spare parts management,changeover exec

28、ution and improvement,Visual Workplace,maintenance of standard procedures,on-line quality,and maintenance notifications(Step 6)Step 7:Ownership of Additional Responsibilities Performance Expectation Participate in Continuous Improvement Projects Minor Maintenance Improvement of Maintenance Plans Equ

29、ipment Redesign/Design004-11.Operators take ownership of additional responsibilities relating to their work areas,not limited to but including participating in continuous improvement projects,minor maintenance,improvement of maintenance plans,and equipment redesign/design(Step 7)7 Steps divided into

30、 3 stages Complete deep cleaning Eliminate sources of contaminants Standardize procedures Implement basic maintenance training for operators Select basic maintenance tasks to be moved to operations Evaluate additional operator responsibilities(QC inspections and changeovers)Incorporate operators in

31、continuous improvement discussions to build ownershipTopic 3:ReviewTopic 4:Progress Measurement Progress Measurement Autonomous Maintenance MetricsMonitoring ProgressPerformance Expectation AM Step Progression ChecklistsNatural team completes self-assessmentWork Area Leader reviews and verifiesSite

32、Leadership certifies004-4.Autonomous Maintenance progress should be monitored at the Focus Factory level through work area self-assessments and Autonomous Maintenance KPI tracking.Monitoring ProgressPerformance Expectation,continued004-4.Autonomous Maintenance progress should be monitoring at the Fo

33、cus Factory level through work area self-assessments and Autonomous Maintenance KPI tracking.Progress should be communicated and celebratedFocus Factory progression is recognized when 80%of work area achieves requirementsTopic 4:ReviewAutonomous Maintenance Step Progress ChecklistsAutonomous Mainten

34、ance Metrics:-Small Groups Meeting Schedule Adherence(%)-Number of Lines with Standard Work(%)-Number of Problem Tags Generated(#)-Problem Tags Resolved(%)-Problem Tags Resolved by Operators(%)Topic 5:Next Steps and Course Review Review FP&R Standards and Guidelines Create an implementation plan to address the business challenges identified-Identify Natural Work Teams-Identify Line Sponsors,Owners and Support Resources-Create Schedule for Small Group meetings Select area to implement AM steps