Autonomous Maintenance

Description:

AM is defined as a partnership between production and maintenance, with the common goal of improving overall equipment performance, availability and yield. Operators learn how their equipment is supposed to operate, what sorts of problems can occur, and how they can help reduce those problems. Typical goals of AM:

To improve OEE by reducing unplanned downtime, and the time to respond to downtime events
Develop a partnership between production and maintenance
Movement of conventional equipment care tasks from the maintenance crew to production personnel
To reduce the overall cost of maintenance

Primary tasks performed during AM include:

Cleaning
Adjusting
Lubrication
Inspection

Whose Asset is it?

All employees play an active role in equipment maintenance

AM is one of the (7) preventative tools used in tgg’s equipment reliability model called STRANDS. As more employees are involved with equipment maintenance abnormalities become more visible. When performing AM, remember these phrases:

Clean to inspect
Inspect to detect
Detect to correct
Correct to perfect

This is an excellent start moving your team from reactive fire fighting to a planned, organized and tested PDCA within maintenance.

Typical Initial AM Event:

This would be performed on a selected piece of equipment which is experiencing low OEE. Lessons learned here could be leveraged throughout the rest of the organization.

Three (3) days planning the event. This is needed to ensure all of the necessary resources are available including people, OEM manuals, cleaning supplies, PPE, etc.
Eight (8) days to conduct the event.
Two (2) days to assess how well the event achieved the goals, to follow up on any open actions, and to plan the next event.

Actual times would vary based upon the circumstances of resource availability, production demands, and complexity of the asset.

Typical Outcomes:

Pictorial work instructions for common AM tasks
Overall index of the respective equipment’s AM tasks broken down by zone, time-frame, and skill set
Start up procedures
Shut down procedures
Safety procedures
Development and tracking of key performance metrics

Define your Problem Statement.

The first step towards breaking your organizational log jams is identifying and verbalizing the challenge you're facing. What are you trying to solve? This simple Problem Statement exercise can have profound implications for your team. It helps you define the issue and gives TGG some sense of where the soft spots could be in your Order to Cash process. We invite you to take a few moments to fill out this form. A TGG consultant will contact you shortly to discuss your Problem Statement and provide some insight on how we may be able to help.