AUTONOMOUS MAINTENANCE

workshop

Upgrading operator capability with basic maintenance skills.

Description

Autonomous Maintenance (Jishu Hozen) refers to TPM activities that involve operators in maintaining their own equipment, independent of the maintenance department. Activities in an AM program include: daily inspections, lubrication, parts replacement, simple repairs, abnormality detection and precision checks.

 

The goals of the AM program are to prevent equipment deterioration, restore equipment to its ideal state, and establish basic conditions needed to keep equipment well maintained. AM is one of the most important building blocks in any TPM program.

 

Companies that have implemented an effective AM program as part of TPM have reported benefits such as significantly reduced downtime, lower cost of maintenance and a higher skilled operative and maintenance workforce. 

In this one-day workshop facilitated by our JIPM-certified TPM consultant, you will learn how to kick start an Autonomous Maintenance program to support your TPM implementation. It includes the step-by-step implementation of the AM Pillar, TPM meetings, one-point lessons, activity board, as well as developing the basic maintenance skills.

Recommended Audience

This course is recommended for Managers, Engineers, Supervisors, TPM steering committee and other operational staff from production, manufacturing, engineering and maintenance.

Methodology

  • Facilitated by JIPM-certified TPM Instructor

  • Lectures, video presentations, group activities and discussions and Q&A

  • Case studies of AM activities and implementation

  • Examples and illutrations of AM practices in industries

Learning Objectives

  1. Understand the key concepts of TPM and Autonomous Maintenance

  2. Understand the six big losses that lower equipment efficiency

  3. Acquire knowledge on how to implement the Autonomous Maintenance activities, step by step

  4. Learn how to use activity boards, team meetings and one-point lessons to promote TPM goals

  5. Understand the critical success factors in sustaining Autonomous Maintenance activities on the shopfloor​

Workshop Outline

  • Implementing the Seven Steps of Autonomous Maintenance

    • Step 1 - Clean and Inspect

    • Step 2 - Eliminate Problem Sources and Inaccessible Areas

    • Step 3 - Draw Up Cleaning and Lubricating Standards

    • Step 4 - Conduct General Inspections

    • Step 5 - Conduct Autonomous Inspections

    • Step 6 - Standardize Through Visual Workplace Management

    • Step 7 - Implement Autonomous Equipment Management

    • Key Implementation Points for AM

    • Role of Management

  • Measuring & Auditing Autonomous Maintenance Performance

    • Possible Metrics for AM

    • Three Important Reasons for Audits

    • AM Audit Checklists

  • JIPM TPM Excellence Criteria for Autonomous Maintenance

  • How to Sustain Autonomous Maintenance

  • Summary

  • Overview of TPM

    • Common Features of Workplaces with Poor TPM Practices

    • Machine Failures Have Many Hidden Causes

    • What is TPM?

    • TPM Principles

    • Why is TPM Important?

    • TPM Goals

    • TPM Pillars & Activities

    • TPM Benefits

  • Introduction to Autonomous Maintenance

    • AM - Is and Is Not

    • AM is a Paradigm Shift

    • AM Supports a Culture Change

    • AM Activities Improve Equipment Efficiency & Upgrade Operator Skills

    • Characteristics of AM Programs

    • Goals of AM

    • Four Equipment-related Skills for Operators

    • AM Approach

    • Activities Beyond the Scope of AM

  • Key Tools for Autonomous Maintenance Team Activities

    • Activity Boards

    • Meetings

    • One-Point Lessons

Award of Certificate

Certificate of Attendance will be issued to participants who have attended at least 75% of the workshop

Duration

1 day

Get started with AM training

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