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Since establishing this website last May of 2007, I have made many efforts to improve this site and provide some useful insights about our common link which is all about improving our equipment reliability and the way we do maintenance. Finally should you be interested to contribute to our articles section or share any comment or feedback, you may email me at Click Here !!!
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Website : www.rsareliaiblity.com Inspired by Change . . . |
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RELIABILITY & MAINTENANCE CONSULTANCY FIRM
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Where the learning just never stops . . .
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RSA
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Our newsletter will be sent out ones a month and provide you with quality issues and resources on our most common link which is all about reliability and maintenance, as well as regular updates about our site. I would like to personally invite you to regularly visit our website and check out updates on our articles and training courses. |
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When an equipment fails, it is the operator that witnessed the failure since they are the people closest to the asset at the time of the failure, the problem is when maintenance arrives at the scene the operator disappear and communication is lost between the two. . . . |
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By Rolly Angeles
Step 4: Develop General Equipment Inspection Procedures: As the first three steps are being accomplished, operator’s involvement on their equipment becomes more evident. Maintenance on the other hand, understands the role operators play in this Autonomous Maintenance transformation. In Step 4, Autonomous Maintenance is taught about the theoretical knowledge they need to know in order to perform their inspection thoroughly. Maintenance should be responsible for transferring this knowledge to operators. Training is an essential part of this step and should be prepared by maintenance in advance or when the Autonomous Maintenance is still in Step’s 1 to 3. This will be a continuous process. Maintenance prepares training materials, cut-out models, one-point lessons, provides one on one coaching and other relevant materials needed for this step. Training will not only be limited to classroom training. In the first three steps of Autonomous Maintenance, maintenance educates the operators about the basic function and safety of their equipment. In this step, maintenance teach operators about nuts, bolts, lubrication, pneumatics, hydraulics and other important things they need to know about their equipment. As the operators’ senses are enhanced in the first three steps to capture equipment abnormality and irregularities, operators learn their way through experience by touching the parts on their equipment, but the operators also need to know the theoretical aspect behind them. Although in Step 3, a tentative standard for cleaning, inspecting and lubrication has been established, operators try to enhance these standards since operators do not only have experienced the process but have also have known the theory and principles. The goal of general inspection is to raise the level of understanding of operators by allowing them to understand both the practical side as well as the theoretical side of their equipment.
While in Step’s 1 to 3 the operator had experience performing initial cleaning detecting abnormalities, identifying hard to clean areas, generate lubricating and cleaning standards as well as basic knowledge about safety and machine function. In Step 4, the focus will be more on training so that operator can have a clear grasp about the basic theory as well as its principles. An example of this is that an operator may detect that a bolt is not properly tightened or loose so the operator will tighten it but what the operator do not know exactly what is the correct amount of torque needed to apply on the bolt and what happens when we over apply the torque in the bolt. Another example is that an operator may know that the level of the oil is below the minimum so the operator makes decision to tap oil into the equipment, but what is the correct viscosity suited for this application. If we speak about grease, what are the different types of grease and up to what corresponding temperatures can they be used. Since the operators have experience the actual inspections, cleaning & performing lubrication on their equipment and had been taught the basic principles on lubrication, bolting and other relevant topics they should know, AM teams with the guide of the PM group finalize the best frequency and interval to perform these activities on their equipment.
The purpose of this step is for the team to understand structures, functions as well as principles in order to learn their optimal conditions to achieve maximum efficiency of the equipment. In this step fundamentals of machine elements, hydraulics, pneumatics, lubrication, bolts, nuts, fasteners, electrical, power transmission, rotating machine elements are learned by operators so that operators can find confidence in themselves in performing the standards generated on lubrication, cleaning and inspection. Unlike the first three steps, Step 4 is probably the longest time to accomplished so what is important is not to rush this activity since we are building the skills of the operators. If done correctly, at the end of this step, the company should see around 60 to 80% reduction in breakdown and other forms of downtime such as errors and assists.
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Issue No. 45 – January 2011 |
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Step 5: Conduct General Equipment Inspection Autonomously: Once Step 4 is completed by the operators, the standards generated in Step 3 are thoroughly analyzed and finalized in order to enhance the inspection process. These inspections that are carried out by operators and maintenance are split in order to avoid redundancy in the process. The general inspection process is organized so that the correct frequency and interval can be derived. Operators prepare an inspection process needed to be done by them on a shiftly, daily, weekly, monthly or even quarterly. The activity of Step 5 is done to generate a sustaining process in the previous steps of Autonomous Maintenance. Once this step is performed, the equipment becomes a shared responsibility for both operators and maintenance. Operators have grasped a full understanding on why they need to perform these activities on their equipment. The inspection is carried out on a regular pattern and equipment failures are minimized at this stage since early failures can now be detected by operators. As operators become full partners in this shared responsibility, maintenance focuses on carrying out their higher phases/steps of their Planned Maintenance activities on their equipment.
The cleaning and lubrication standards set in Step 3 and the tentative inspection standards prepared for each given category in Step 4 are now combined in Step 5 where they are combined into a unified Autonomous Maintenance Standard. Cleaning, inspection and lubrication standards should be reexamined to accomplish a higher check efficiency and eliminate possibility of human errors. If problems occurs operators work with maintenance to develop inspection points that can prevent the problem from recurring. At this step, operators continue to think of ways to shorten the time to perform cleaning, lubrication and inspection on their assets. Because of the training gained from the previous steps of Autonomous Maintenance, operators skills are truly enhance. At this step, operators are capable of detecting abnormality and irregularities in their equipment and what to do in case they spot one. It is important to consolidate the activities performed by both maintenance and operators on the equipment on this step to avoid duplication and redundancy on the maintenance side. If such activities such as cleaning, lubrication and tightening activities is included in the current PM lists CMMS is revised and responsible person is changed from maintenance to operator since this will be carried out by the AM teams. The Inspection being finalized and generated on this stage is very much different from the traditional checklist provided by maintenance since operator understands now the value of doing it.
Step 6: Manage Systematic Autonomous Maintenance in the Workplace: As the operator completes the first five steps of Autonomous Maintenance activities equipment starts to improve and failures are reduced dramatically. Operators now focus on how to improve their workplace by using simply principles of 5’s, visual control management and housekeeping. Tools are properly organized, cleaning materials are easily accessible, jigs tools and fixtures for conversion are properly stored and so on. In simple layman’s term, let us say that the first 5 steps refer to cleaning and inspecting inside your house. In this step, the owner likewise would like to maintain his backyard and clean up unnecessary things in his garage. These things are done in order to provide orderliness in the workplace. People working for quite a number of hours can stress and fatigue themselves easily. Human stress is accelerated if the environment they are exposed to is a mess. Also, as Autonomous Maintenance is a continuous effort, the operators device simple yet innovative ways to improve ways of inspection, lubrication and cleaning in their equipment with the effective use of visual controls.
All activities geared in completing Step 1 to 5 focused on reducing equipment breakdown. In Step 6, AM activities are focused on aiming for Zero Waste and Zero Defects. This can be achieved by not only improving equipment, but as well as work methods, operators human senses, application of visual controls and Poka-Yoke or Mistake Proofing devices to eliminate defects. Operators should not only be keen in determining abnormalities in the equipment but also should learn to distinguish materials that can contribute to waste and quality defects. Step 6 aims to foster development of operators knowledgeable in matters of quality, equipment and procedures for fully implementing autonomous supervision without the need for full detailed instruction by supervisors and managers. Although most industries want an equipment with minimum breakdowns, more industries are interested in matters of quality since achieving Zero Defects in quality is much more difficult to achieve than Zero Unplanned Breakdowns.
Step 7: Achieve Empowered Autonomous Maintenance Workforce: This is the last step of Autonomous Maintenance activities where the operators become self-sustaining. As operators become empowered, minimal assistance is required. The operators have already achieved a stage of being fully competent on their equipment where they can make their own decisions and conduct improvement initiatives with the other pillars of TPM such as Planned Maintenance and Focused Improvement in eliminating other losses in their equipment. The operator has fully been transformed into this final stage as being empowered and highly motivated workforce where they challenge themselves to further enhance the inspection process and generate further improvements in their equipment as well as challenge themselves to further improve their equipment indices. Autonomous Maintenance become full-pledged partners with maintenance and join them in the process of further improving their equipment by analyzing causes of failures and other related product quality issues. You just cannot imagine what the power of this workforce can achieve when you reach this stage of Autonomous Maintenance. Both human and equipment side are improved. Better operators can yield better performance. Operators know what is best for them and their equipment and the best part is that operators join maintenance in teaching other operators about this transformation.
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At this last stage operators become independent, skilled, confident and well motivated and can perform simply repairs and equipment restoration by training them in repair skills. Operators improvement skills are raised as they join improvement initiatives and projects in eliminating the 6 big equipment losses on their machines. In Step 7 knowledgeable operators conduct autonomous supervision and follow the standards set by themselves on the orderly shop floor, where any deviation from the normal or optimal operating condition is detected at a glance by the AM team. Completion from Step 0 to Step 7 is a very long journey to complete and maintenance should have the patience since if this is done correctly breakdowns and quality defects will dramatically be reduced but if done incorrectly failures will revert back, operators becomes saturated and enthusiasm of the team diminished as frontline people, engineers, maintenance including plant managers are being replaced every year, what is important is to sustain the enthusiasm of the team on every step that the team will undertake.
TPM believes that constant improvement has to come from the individual and that empowerment is the only way to get the people to adopt constant improvement as a way of life in individual business. In other words, the way to empowerment is to create a work system based on principles that will enable people to take charge of the situation
TPM BELIEVES THAT . . . . The people closest to the work knows best how to perform and improve their day to day operations. Oftentimes operators do not perform inspection in their equipment. Maintenance develop the checklist, but operators simply don’t perform the checks. This seems to be the main complaint of the maintenance people, operators do not resist change, they just do not want to be dictated by anyone. The secret is to let the maintenance guide them into understanding their own equipment, once they learn, they will take care of their own equipment. The key is to let the maintenance understand that operators are capable of developing their own checklist. And if operators develop their own checklist, it is guaranteed that they will perform it themselves. Remember that Autonomous Maintenance cannot be forced on operators, it will require a tremendous amount of initiative, guts, patience and humility to develop self-directed and empowered operators and it will take 3 to 5 years to achieve this stage but the time spent will be truly worth the time.
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RELIABILITY NEWSLETTER |
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RSA |
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Inspired by change |
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• Gallery: New pictures for 2011 added from the gallery portion. • Newsletter: Aug. 2011 Edition finally released to our subscribers. Email me if you want to subscribe to our Newsletter. • 2012 Training Schedule: If you are interested to attend in any of our public workshop and master class for 2012. Send us an email or register online. • WCM Book: If you’re interested in buying the book on World Class Maintenance, The 12 Disciplines. Send me an email to reserve. WCM Book is now available. Get your copy now. • In-house Training :Should your industry be interested for in-house trainings we are now accepting regular schedules for in-house training for both local and international countries on courses that we currently offered. Contact us |
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World Class Maintenance Management - The Twelve Disciplines Book is now available here. This is not only about the technical jargon on reliability and maintenance, it is a book that makes every single maintenance proud that they belong to the maintenance function. If you have been living through the day to day pressures of doing maintenance then this is your story. If you are interested in this book, send me an email. Click Here ! |
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Select the courses of your choice and it can be made available in CD . Click Here ! |
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We are very much flattered and humbled by your feedback and testimonies. Your messages are the main reason for allowing us to stay in this business. With all humility we say thank you and rest assure that we are continuously improving. Without your support in our training there won’t be us. Read More ! |
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• If your industry is interested to join and participate in any of our upcoming public training and workshop for this year 2012 you may send us an email or simply fill out the registration form provided on our schedule site. You may Click here to visit our schedule training for 2012 Schedule. |
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Our Reliability Newsletter will be provided once a month to our valued subscribers. It provides highlights as well as issues and lessons regarding our most common link which is all about improving the reliability of equipment. |
