AUTONOMOUS MAINTENANCE

Autonomous maintenance slide

1. 7 STEPS OF AUTONOMOUS MAINTENANCE (AM)

2. The objectives of this module are: Overview the autonomous maintenance (AM) Step 1 to Step 2 Introduce the AM Step 3 which is cleaning & lubrication standard Introduce the AM Step 4 which is overall equipment inspection Introduce the AM Step 5 which is AM Standard Introduce the AM Step 6 which is process quality assurance Introduce the AM Step 7 which is supervision.

3. AM OBJECTIVE Knowledgeable Operators Optimal Equipment Condition Zero Accident + Zero Defect + Zero Downtime Prevention Occurrence of abnormalities Indication of abnormalities Orderly Shop-floor

4. ZERO DEFECT ZERO DOWNTIME ZERO ACCIDENT

5. AUTONOMOUS MAINTENANCE - STEP 1 Major activities are :- Thoroughly clean equipment and its surrounding. Remove all unnecessary material. Detect and record the abnormalities using 5 senses ( eyes, nose, hand, mouth & ears) Cleaning as Inspection, Lubrication & Tightening

6. AUTONOMOUS MAINTENANCE - STEP 1 Major activities are :- Thoroughly clean equipment and its surrounding. Before start, prepare machine mapping and cleaning checklist to record cleaning tasks and time. Begin cleaning with the most contaminated area. Remove all layers of dirt and grime built up. Identify difficult areas to do cleaning, lubrication & tightening. Open previously ignored covers, guards, underground pits etc. Clean also accessories such as control box, conveyor, tanks etc. Record cleaning time in the checklist. Cleaning as Inspection, Lubrication & Tightening

7. AUTONOMOUS MAINTENANCE - STEP 1 Major activities are :- 2. Remove all unnecessary material. Perform SEIRI to remove unnecessary items. All obsolete items need to be removed. All leftover components from previous modification need to be disposed. Any unused or temporarily disconnected items need to be removed such as unused switch covered with vinyl tape, pressured unused pipes etc. NEVER neglected unnecessary pieces of equipment. THROW them AWAY. Cleaning as Inspection, Lubrication & Tightening

8. AUTONOMOUS MAINTENANCE - STEP 1 Major activities are :- 3. Detect and record the abnormalities using 5 senses ( eyes, nose, hand, mouth & ears) Cleaning as Inspection, Lubrication & Tightening Detect any fuguai on the equipment Use Blue Tag and Red Tag for easy action. Identify and record all sources of contamination. Restore defective area in equipment inclusive of temporary fixes such as piping with vinyl tape. Cleaning is inspection. Replace defective parts in equipment such as broken glass on gauge. AM team member should be able to differentiate between normal and abnormal situation and also understand equipment deterioration

9. AUTONOMOUS MAINTENANCE - STEP 1 The purpose of cleaning from the equipment perspective is to :- Expose hidden defects or abnormalities by removing contaminant. Restore defective area in equipment. Identify the source of contaminants. The purpose of cleaning from the human perspective is to :- Familiarize operators with the cleaning task. Group leaders learn leadership. To look & touch every corner of the equipment to promote curiosity and questions. Learn that “Cleaning is inspection”. Cleaning as Inspection, Lubrication & Tightening

10. AUTONOMOUS MAINTENANCE - STEP 1 DELIVERABLES Team formation AM Display board OOE Chart (BEFORE) Machine mapping Cleaning checklist 6. Fuguai Detection & Restoration Chart 7. Record of Difficult area to do cleaning 8. Record of Sources of contamination 9. AM Kaizen 10. One Point Lesson Cleaning as Inspection, Lubrication & Tightening

11. AUTONOMOUS MAINTENANCE - STEP 2 Major activities are :- Eliminate the sources of contamination. Eliminate or minimize inaccessible areas. Reduce cleaning time by improving difficult cleaning area issue. Identifying Root Cause of the Dirtiness & Contamination

12. AUTONOMOUS MAINTENANCE - STEP 2 Major activities are :- 1. Eliminate the sources of contamination. Review sources of contamination identified earlier in Step 1 Conduct a WHY-WHY analysis to review the sources. Brainstorm for the best countermeasure. Implement the corrective actions. Verify result of the actions. Change equipment SOP if needed Prepare OPL to train others. AM members should be able to learn equipment mechanism. Identifying Root Cause of the Dirtiness & Contamination

13. AUTONOMOUS MAINTENANCE - STEP 2 Major activities are :- 2. Eliminate or minimize inaccessible area. Inaccessible areas resulted in longer cleaning time or no cleaning at all. Inaccessible or difficult cleaning areas need to be resolved. Conduct a WHY-WHY analysis, brainstorm the countermeasure, implement the corrective actions and verify result. Sometime no considering on cleaning during machine design. If can’t minimize, need method for cleaning inspection such as transparent cover or cover with small opening. Identifying Root Cause of the Dirtiness & Contamination

14. AUTONOMOUS MAINTENANCE - STEP 2 Major activities are :- 3. Reduce cleaning time. Use cleaning checklist in Step 1 to become tentative SOP. Revise cleaning time target accordingly based on improvement. Improve cleaning method to further reduce the time. Keep on improving until reach desired time. KAIZEN Identifying Root Cause of the Dirtiness & Contamination

15. AUTONOMOUS MAINTENANCE - STEP 2 The aims from the equipment perspective is to :- Prevent contaminants from generating and sticking to the equipment. To ensure cleanliness so as to improve maintainability. The aims from the human perspective is to :- Learn the motion & working mechanism of machinery. Learn method to improve equipment by eliminating contaminants. Encourage interest to improve equipment. Gain satisfaction & confidence to improve equipment. Identifying Root Cause of the Dirtiness & Contamination

16. AUTONOMOUS MAINTENANCE - STEP 2 Generated by the technical restrictions of machinery Metal chip, scraps, fluid, plastic flashing from molding parts and rubber curing, mist from painting product. Generated due to improper operation and maintenance of equipment. Leak lubricant, hydraulic oils, cutting fluids, work piece dropped from equipment and fluid leaked from pipe. Generated by factors other than equipment Dirt, thread and lint from personnel, rags and gloves. wrapping paper, insect and dust entering from outside. TYPES OF SOURCES Identifying Root Cause of the Dirtiness & Contamination

17. AUTONOMOUS MAINTENANCE - STEP 2 OOE Chart (AFTER) Tentative Cleaning Standard (general & difficult areas) AM Kaizen One Point Lesson Improvement Activity Tracking Cleaning Time Reduction Chart DELIVERABLES Before After KAIZEN EXAMPLES STEP 1 STEP 2 STEP 3 MAY JUNE JULY AUG SEPT OCT NOV DEC JAN. 01 FEB MAR INITIAL CLEANING Identifying Root Cause of the Dirtiness & Contamination

18. AUTONOMOUS MAINTENANCE - STEP 2 PRIORITIZATION THROUGH PARETO ISHIKAWA DIAGRAM WHY-WHY ANALYSIS IMPROVEMENT PROCESS FLOW CORRECTIVE ACTION REPORT KAIZEN REPORT METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

19. AUTONOMOUS MAINTENANCE - STEP 2 PRIORITIZATION THROUGH PARETO What Is a Pareto Chart? • Bar chart arranged in descending order of height from left to right. • Bars on left relatively more important than those on right • Separates the "vital few" from the "trivial many" (Pareto Principle) METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

20. AUTONOMOUS MAINTENANCE - STEP 2 PRIORITIZATION THROUGH PARETO Why Use a Pareto Chart? • Breaks big problem into smaller pieces • Identifies most significant factors • Shows where to focus efforts • Allows better use of limited resources METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

21. AUTONOMOUS MAINTENANCE - STEP 2 PRIORITIZATION THROUGH PARETO METHODE ANALYSIS 100% 50% 11 7 6 5 4 4 3 1 Bocor Hilang rosak bengkok gegar bising selerak karat JENIS MASALAH JUMLAH FUGUAI 10 20 30 40 50 Identifying Root Cause of the Dirtiness & Contamination

22. AUTONOMOUS MAINTENANCE - STEP 2 2. ISHIKAWA DIAGRAM What is Ishikawa/Fishbone Diagram? A graphic tool that helps identify, sort, and display possible causes of a problem or quality characteristic. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

23. AUTONOMOUS MAINTENANCE - STEP 2 2. ISHIKAWA DIAGRAM Benefits of Using Ishikawa Diagram • Helps determine root causes • Encourages group participation • Uses an orderly, easy-to-read format • Indicates possible causes of variation • Increases process knowledge • Identifies areas for collecting data METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

24. AUTONOMOUS MAINTENANCE - STEP 2 ISHIKAWA DIAGRAM Basic Layout of Ishikawa/Fishbone Diagram using 4M methods : Man, Machine, Method & Material METHODE ANALYSIS PROBLEM /EFFECT MAN MACHINE METHOD MATERIAL cause cause cause cause Identifying Root Cause of the Dirtiness & Contamination

25. AUTONOMOUS MAINTENANCE - STEP 2 ISHIKAWA DIAGRAM What Next? From possible causes that has been identified, run assessment to determine which causes are true and which are false. The assessment is to check validity of the causes either the certain controls are already in place or engineering evaluation to determine the validity of the causes. The true causes then subjected to Why-Why Analysis to further analyzed on actual root causes of the problem. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

26. AUTONOMOUS MAINTENANCE - STEP 2 3. WHY-WHY ANALYSIS What is Why-Why Analysis? it is question-asking method used to explore the cause relationship underlying a particular problem. the goal is to determine root causes of the problem based on 5 times “why” but may be more or less. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

27. AUTONOMOUS MAINTENANCE - STEP 2 WHY-WHY ANALYSIS. can be used together with fishbone diagram or in tabular form. METHODE ANALYSIS Example of Why-Why in tabular form Problem : Machine Rusty Why 1 Why 2 Why 3 Why 4 Why 5 Question Why rusty? Why exposed? Why not applied? Why nobody? Why do not know? Answer Expose to environment No grease applied Nobody applied Do not know who should apply No checksheet Identifying Root Cause of the Dirtiness & Contamination

28. AUTONOMOUS MAINTENANCE - STEP 2 4. IMPROVEMENT PROCESS FLOW METHODE ANALYSIS PREPARE SHORTLIST PROBLEM WITH THE MEMBERS GET MANAGER TO ASK FOR THE ASSISTANCE FROM OTHERS DEPARTMENT TRIAL CAN BE RACTIFY BY OWN ? SELECT THE BEST COUNTERMEASURE SUCCESS? IMPLEMENTATION CHANGE S.O.P AND PREPARE O.P.L – TRAIN TO OTHER MEMBERS. COMPLETED YES YES NO NO NEW IDEA? AND ANY COST SAVING? FILL UP ESS FROM AND SEND TO ESS COMMITTEE. YES A A Identifying Root Cause of the Dirtiness & Contamination

29. AUTONOMOUS MAINTENANCE - STEP 2 5. CORRECTIVE ACTION REPORT it is one of problem solving methodology report use step-by-step approach to tackle any problem/defect. it consists of 6 steps: Problem Definition Containment Action Root Cause Analysis Corrective Action Implementation Verification of Corrective Action Prevent Recurrence. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

30. AUTONOMOUS MAINTENANCE - STEP 2 CORRECTIVE ACTION REPORT 1. Problem Definition Problem is usually chose by prioritization through Pareto Diagram or is identified by customer. Define or specify the problem by identifying in specific and quantifiable manners. Use the “5W2H” in identifying the problem - Who, What, Where, When, Why, How & How Many. Examples : Rusty Y-axis ball screw found at Machine A Line 1 by operator during night shift last night. 2 ball screws of Y-axis involved. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

31. AUTONOMOUS MAINTENANCE - STEP 2 CORRECTIVE ACTION REPORT 2. Containment Action It is an immediate action usually taken place within 24 hours before analyzing the root causes. The short-term action is done to isolate the problem from any customer externally or internally until permanent action done. Examples : a) Immediately sand blast the rusty area and apply grease. b) Add inspection station if the problem due to product defect c) Do sorting process at Warehouse, WIP, In-transit & Customer side if the problem due to product defect. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

32. AUTONOMOUS MAINTENANCE - STEP 2 CORRECTIVE ACTION REPORT 3. Root Cause Analysis Identify all potential causes that could explain why the problem occurred. Also identify why the problem has not been noticed at the time it occurred. All causes shall be verified or proved, not determined by unclear brainstorming. Tools usually used are : a) Ishikawa Diagram b) Why-Why Analysis METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

33. AUTONOMOUS MAINTENANCE - STEP 2 CORRECTIVE ACTION REPORT 4. Corrective Action Implementation After the root cause has been identified, propose possible corrective actions. Find the best corrective action to be implemented as permanent corrective action through decision matrix. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

34. AUTONOMOUS MAINTENANCE - STEP 2 CORRECTIVE ACTION REPORT 5. Verification of Corrective Action Quantitatively confirm that the selected corrective action will resolve the problem. The verification process should be validated by customer and superior. The data before and after corrective action should be captured to validate the action taken. Trend chart can be used as an objective evidence to show improvement after implementing the corrective action. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

35. AUTONOMOUS MAINTENANCE - STEP 2 CORRECTIVE ACTION REPORT 6. Prevent Recurrence The preventive actions should be in placed to make sure the same problem will not happen again. The same process at different production line also need to benchmark the corrective action taken in order to prevent the same problem happen. Usually tackle “systemic issue” rather than “local issue”. Examples : a) Improve management system b) Improve practices and procedures c) Implement real time monitoring system. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

36. AUTONOMOUS MAINTENANCE - STEP 2 6. KAIZEN REPORT it is Japanese word for “improvement” or “ change for the better.” it is practices focus on continuous improvement of processes in manufacturing, engineering, business management, etc. the purpose is to eliminate waste. it involves all employees from CEO to operators. METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

37. AUTONOMOUS MAINTENANCE - STEP 2 6. KAIZEN REPORT concept of improvement using Deming Cycle : PDCA and in Autonomous Maintenance use CAPD. root cause analysis such as Ishikawa Diagram and Why-Why Analysis. Six Sigma methodology using DMAIC approach. DMAIC : Define – identify the problem Measure – measure current state of problem Analysis – root cause analysis Improve – implement corrective action Control – preventive action and monitoring METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

38. AUTONOMOUS MAINTENANCE - STEP 2 KAIZEN REPORT Example of Kaizen projects in Cleaning Time Reduction Remove all the sources of contaminations Improve cleaning method Modify equipment to make cleaning task easier Modify equipment to make inspection easier METHODE ANALYSIS Identifying Root Cause of the Dirtiness & Contamination

39. AUTONOMOUS MAINTENANCE - STEP 2 KAIZEN REPORT main feature in Kaizen report is condition before and after improvement in term of photo or sketch. other features include the improvement result, person in-charge, date of implementation, title, etc. examples of condition before and after improvement as below: METHODE ANALYSIS Before After Before After Identifying Root Cause of the Dirtiness & Contamination

40. AUTONOMOUS MAINTENANCE - STEP 3 The aims from the equipment perspective is to :- Rectify difficult lubricating areas. Apply visual controls. Maintain basic equipment conditions to establish deterioration prevention system. The aims from the human perspective is to :- Set cleaning and lubrication standard. Understand the importance of following rules and autonomous supervision. Encourage awareness of one’s own roles and of teamwork . CLEANING AND LUBRICATING STANDARD

41. AUTONOMOUS MAINTENANCE - STEP 3 General Objective is to achieve :- ZERO DOWNTIME Major activities are :- Conduct education for lubricating activities. Develop overall lubrication inspection. Establish lubrication control system. Set cleaning and lubrication standards. CLEANING AND LUBRICATING STANDARD

42. AUTONOMOUS MAINTENANCE - STEP 3 1. Conduct education for lubrication activities. Prepare teaching material by Maintenance group and plan roll out training. The material should covers: Basic theory on lubrication. Major rotating & reciprocating parts. Structure & function of the lubricating tools & apparatus. Lubrication control manuals. Lubrication inspection manual and check sheet. Audiovisual materials, One-Point-Lesson and cut away models. Lubrication types, flow diagram and labels. Lubrication practices in the floor. CLEANING AND LUBRICATING STANDARD

43. AUTONOMOUS MAINTENANCE - STEP 3 2. Develop overall lubrication inspection Prepare lubrication inspection checklist (with maintenance) Identify lubrication points and surfaces (with maintenance) Allocate lubrication routine tasks (with maintenance) Identify & rectify lubrication difficult areas Identify & rectify sources of contamination (lubrication) Identify & rectify equipment fuguai (lubrication) Use of WHY-WHY analysis for countermeasure Record lubricating time in checklist CLEANING AND LUBRICATING STANDARD Before After Effect Lubricating Time Reduction Trend Minutes High Lubricating Time Trend Month BEFORE KAIZEN AFTER KAIZEN

44. AUTONOMOUS MAINTENANCE - STEP 3 3. Establish lubrication control system Prepare lubrication system flowchart (maintenance) Supply only clean and correct viscosity of lubricant Apply lubricant using correct tools at designated points. Apply lubricant at correct interval and amount. Update lubrication checklist with lubrication control. Apply visual color control for lubrication such as labels, viscosity, oil level, lubricating points etc. CLEANING AND LUBRICATING STANDARD

45. AUTONOMOUS MAINTENANCE - STEP 3 4. Set cleaning and lubrication standards. Review tentative cleaning standard in Step 2 Review lubricating checklist to become lubrication standard Combine both standards into one standard Make sure time targets designated are achieved. Initiate further Kaizen to achieve time targets. CLEANING AND LUBRICATING STANDARD

46. AUTONOMOUS MAINTENANCE - STEP 3 SET LUBRICATION CONTROL RULES Integrate & minimize lubrication types & viscosity. Assign code # and color identification for each lubricant. Specify lubricant level ( min/max). Specify lubricant control rules – PIC, storage, inventory, container, supply & disposal spec. Prepare samples for demo purpose if necessary. TEACHING MATERIAL Basic theory on lubrication. Major rotating & reciprocating parts. Structure & function of the lubricating tools & apparatus. Lubrication control manuals. Lubrication inspection manual and check sheet. Audiovisual materials, One-Point-Lesson and cut away models CLEANING AND LUBRICATING STANDARD PREPARATION BY MAINTENANCE DEPARTMENT Before start AM Step 3, Maintenance must make necessary preparation.

47. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD PREPARATION BY MAINTENANCE DEPARTMENT TYPE COLOR CODE CLASSIFICATIONS MAJOR SERVICES Hydraulic Oil Yellow 32 ISO VG 32 Low pressure hydraulic system: air lubricator. Yellow 56 ISO VG 56 High pressure hydraulic system Machine Oils Blue 32 ISO VG 56 Sliding surface for common machines. Blue 68 ISO VG 68 Sliding surface for specific machines. Gear Oil Green 6 ISO VG 6 Main Shaft bearing for grinding maching Green 32 ISO VG 32 Common reduction gear for >500rpm. Compressor Oils Orange 26 ISO VG 26 Screw Compressor. Greasers White B 1 NLGI No 1 Sliding parts & bearing for common machines Lubricants Type

48. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD PREPARATION BY MAINTENANCE DEPARTMENT Lubricants labels STANDARD LABELS FOR FLUID 3 1 1 Responsible : Maintenance Production Day Month Production Every 3 month Production Every 1 day Maintenance Every 1 month GREASE LUBRICATION COOLANT

49. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD PREPARATION BY MAINTENANCE DEPARTMENT Label Samples Inspection by Maintenance for every 4 months Inspection by Production for every 1 day Type of Lubricant Lubricant level (min/max)

50. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD PREPARATION BY MAINTENANCE DEPARTMENT ROUTINE LUBRICATION TASK 1) Lubrication using : Hand lubricators Pressure guns Brushes 2) Oil level inspection and lubrication at reservoir and air lubricators. 3) Check temperature and oil level and lubrication at: Reduction gears Change gears Pumps Compressor 4) Inspection of lubricating surface

51. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD IDENTIFYING LUBRICATION POINTS AND SURFACE The lubricating points and surfaces must be identified through : Equipment inspection Review drawing Review vendor’s manual Do not overlook points such as thick paint applied to lubricating surface and not lubricated for a long time. During inspection on lubricating practice, defective parts can be detected also. The list on equipment lubrication should be prepared inclusive of lubrication points and surfaces, type of lubricants, intervals and methods.

52. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD IDENTIFYING LUBRICATION POINTS AND SURFACE Lubrication Point (Point at which to supply lubricant) Lubrication Surface (Sliding parts which require lubrication such as reciprocating, rotating and chains item.) Identify all lubricating points and surfaces.

53. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD LUBRICATION CONTROLS Supply clean lubricant. Conforming to operating condition. Through designated lubricating points. To designated lubricating surfaces. At designated time. In proper quantity. Apply visual control

54. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD LOSSES DUE TO POOR LUBRICATION ACTIVITIES Examples : Under lubrication at machine Operator do extraordinary lubrication at machine. Lubrication type – follow supplier’s instructions only Different lubrication type and brand used. Change contaminated oil at irregular intervals.

55. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD FUGUAI / ABNORMALITIES AT MACHINE EXAMPLE OF LUBRICATION FUGUAI: Clogged lubricating system. Contamination at lubrication point & surface. Excess, shortage of leakage of lubricants Oxidation or contamination by dust, dirt, water or other foreign material No platforms and handrails at lubricating points. Lubricating point difficult to reach, too high or too low. Lubricating points are all over the place – longer time required. Lubricating pipes are damage. Lubricating surfaces are over or under lubricated. Lubrication drip from lubricating surface and become new source of dirtiness.

56. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD DIFFICULT LUBRICATING AREAS LONGER TIME ARE REQUIRED TO Carry out lubricating task. Inspect quantity of lubricants Inspect the condition of lubricating surface. Lubricating Time Reduction Trend Minutes High Lubricating Time Trend Month LUBRICATING TIME MONITORING BEFORE KAIZEN AFTER KAIZEN

57. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD KAIZEN – Difficult Areas Before After Effect

58. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD CLEANING SOP NO LOCATION CLEANING STD CLEANING METHOD DUR SHIFT DAY WEEK MONTH 1 Main Body & Surrounding No metal chips or foreign material Wipe clean with damp rags 15 min 2 Oil Pump and valves No oil leakage & dirt Wipe clean with damp rags 10 min 3 Pedestal No grease & other contaminants Remove with scrapper and sweep up 5 min 4 Pee-hole Clear Indication of oil Wipe clean with damp rags 3 min 5 Underground pit No oil leak & dirt Wipe clean with damp rags 30 min Inspection during cleaning No bolt loose at ring joints for centralized lubrication system. No bolt loose or oil leak at distribution valves. No bolt loose at guide plates

59. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD LUBRICATING SOP NO LOCATION LUBRICATION STD TYPE OF LUBRICANT METHOD DUR SHIFT DAY WEEK MONTH 1 Air Lubricator Within ranges as specification Blue 32 Hand oiler 10 min 2 Worn Gear Within ranges as specification Green 150 Oil Container 5 min 3 Main Gear Sufficient Oil film White C2 Scrapper 5 min 4 Oil Pump Within ranges as specification Green 68 Oil Container 3 min 5 Inspection during lubrication No play in safety cover for main gear No anchor bolt loose for grease supply pump Adequate air supply for air lubricator

60. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD VISUAL CONTROL To make lubrication and inspection task easier. Paint the oil containers, lubricators and pressure guns with colors assigned. Differentiate type of lubricant by viscosity. Place lubricant labels at every lubricating points. Mark lubricant ranges at air lubricator and oil level gauges. Apply heat sensitive tape at pillow blocks, speed reduction gears, change gears or other critical parts to check over heating.

61. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD VISUAL CONTROL To monitor the improvement done by the team. Reduced Reduced Reduced Reduced

62. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD VISUAL CONTROL Quality of the products will be shows improvement and the OEE will be increasing Increasing

63. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD AM 3 IMPROVEMENT CYCLE C A P D Identify lubricating points. Detect fuguai (defective area) – in relation to lubrication. Identify difficult lubricating area. Establish cleaning standard. Establish lubrication standard. Do cleaning based on cleaning standards. Do lubrication based on lubrication standards. Check Action Plan Do 1 2 3 4 C. A. P. D CYCLE IS REPEATED UNTIL TIME TARGET ARE MET. Restore the defective area. Eliminate or modify – difficult lubricating area.

64. AUTONOMOUS MAINTENANCE - STEP 3 CLEANING AND LUBRICATING STANDARD DELIVERABLES OOE Chart (AFTER) AM Kaizen Lubrication inspection checklist Improvement Activity Tracking Lubrication Time Reduction Chart Fuguai Detection (lubrication) Record of Difficult area to do lubrication Record of Sources of contamination Lubrication system flowchart Combined cleaning/lubrication standard. KAIZEN

65. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD Major activities are :- Identify inspection category on equipment such as fastener, electrical, hydraulics, pneumatics etc. Conduct education and practice. Develop overall inspection. Rectify difficult inspection areas. Set tentative inspection standard.

66. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD General Objective is to achieve :- The aims from the equipment perspective is to :- Detect and restore equipment defects Thoroughly apply visual control Improve difficult inspection areas Routine inspection to maintain equipment The aims from the human perspective is to :- Learn inspection and easy servicing skills Learn leadership. Learn analysis of data. OBJECTIVES ZERO DOWNTIME

67. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD NECESSITY OF OVERALL INSPECTION Reality of Inspection Operators’ inspection were not effective due to lack of skill, motivation, feasibility etc. Maintenance staff creates standard and forces operator to perform inspection. The inspection document includes too many checkpoints without consider operator’s workload and skill. Maintenance staff just completes the check sheet and pass to Production for operator to do routine inspection. Maintenance staff busy to settle frequent breakdowns and no time to perform routine inspections. Ordinary operators can NEVER perform effective inspections due to their backgrounds.

68. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD NECESSITY OF OVERALL INSPECTION Why Most Standards Ineffective Due to lack of consideration as follow: What must be inspected? How much time needed for inspection? How long are the inspection intervals? What skill does operator needs? Any way to make inspection easier? Is it feasible to conduct inspection together with cleaning/lubrication? Is inspection task allocated properly between Production and Maintenance staffs? Operator is not taught about negative impact on insufficient inspection to equipment and product quality. Operator will not generate motivation under these conditions.

69. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD NECESSITY OF OVERALL INSPECTION No Skill is Provided The largest obstacle in effective inspection is lack of skill by operator. Most criteria for inspections are by visual which are difficult to quantify. Operator need to acquire skill on abnormalities and able to differentiate between normal and abnormal conditions such as on abrasion, play, noise, vibration etc. It is essential to train operator on this kind of fuguai in order for them to detect the fuguai during routine operating, cleaning and lubrication tasks. This is called “technical sixth sense.”

70. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD NECESSITY OF OVERALL INSPECTION No Opportunity is Created Some management only focus on quantity of products without considering equipment conditions. This attitude causes an increase in minor stoppage and breakdown along with output reduction. Even highly skilled & motivated operator failed to do effective inspection due to equipment minor stoppage or reworking defect products. Management role is to provide opportunity for operator to do effective inspection in order to get enough output. This is fall under Management Commitment & Support.

71. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD NECESSITY OF OVERALL INSPECTION The Operator’s Potential Operator need to be educated in each category of inspection. The roll out education need to be in easily understood language. Once operator acquired skill and knowledge, they will commit themselves to the important role of routine inspection. Education in AM focuses on raising up the technical level of ALL members not eliminating the dull one. After acquiring the necessary education, the operator has a potential to create their own check sheet and perform effective routine inspection beside detecting and restoring fuguai .

72. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Teaching materials Check sheets The Procedure 1. Preparation. Determine categories to overall inspection Prepare teaching materials Plan schedules Maintenance staff Maintenance staff Maintenance staff Eg: fastener, electrical, pneumatics, hydraulics, etc Inspection manuals

73. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION The Procedure 2. Education. Conduct group leaders education Prepare roll-out education Conduct roll-out education Maintenance staff Group leaders/managers Group leaders Inspection practice at shop floor equipment

74. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION The Procedure 3. Overall inspection Difficult area Fuguai list Conduct overall inspection Conduct AM group meeting Rectify equipment defects AM group members AM group members AM group members & Maintenance staff Related equipment available Sources of contamination list

75. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION The Procedure 4. Finishing. Set tentative routine inspection standard Check operator’s inspection skill Review inspection standard AM group members Group leaders AM group members & Maintenance staff improvement on inspection time & difficulties Skill evaluation matrix Routine inspection standard

76. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Preparation – Determine Category The Maintenance Department responsible to determines the category for overall inspection and basic education policy. It will covers on detail inspection criteria and knowledge to achieve proper equipment operation, setup and adjustment. In addition to lubrication inspection as per Step 3, it is recommended to has at least 4 more categories of inspection depend on the company maintenance policy. The potential categories as follow: fastener electrical pneumatics hydraulics coolant etc

77. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Preparation – Teaching materials The basic teaching materials needed are check sheets and manual for overall inspection. For each category Maintenance staff will prepare the details of inspection to be checked by operator visually or by simple measuring equipment in a check sheet. The items in a check sheet will be used to prepare overall inspection manual. The overall inspection manual should consists of equipment basic structure, function, nomenclature, inspection methods, areas to be inspected, causes of deterioration, countermeasure to problem etc.

78. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Example of Overall Inspection Check sheet

79. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Example of Overall Inspection Manual

80. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Example of Overall Inspection Manual

81. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Preparation – Plan schedules Most companies allocate several months to any one category of overall inspection which will give one year to complete all. The schedule must be set up to allow operators to learn knowledge and skill within reasonable time frame and to link between education and actual practice. Other consideration: availability of group leaders, allocation of operators, training facilities and production target plan. Educational program is a long-term process, so support from top management is needed plus budgetary allocation.

82. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Education – Conduct for Group leaders Group leaders education need to be conducted by Maintenance personnel. Key areas to cover: Educational aid: Cutaway models, drawings, sketches, etc. parts names, structure and function of equipment problems and corrective actions keypoints , methods and criteria for inspection inspection practice at shop floor equipment roll-out education methods

83. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Education – Prepare roll out Group leaders may revise the education package to tune with their equipment with maintenance help. The Group leaders also need to understand on their equipment and can teach with confidence. Training and practices for this Step 4 will be developed over a long period, so it is important to maintain the learning momentum. Some of the below ideas may be used : actual disassembly and reassembly of equipment hands-on inspection of any problem sites contest for discovery of defective parts or equipment etc.

84. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Education – Roll out for operators Roll out education need to be conducted by group leaders and inspection practice by operators. Key areas to cover: Educational aid: Cutaway models, drawings, sketches, etc. parts names, structure and function of equipment problems and corrective actions keypoints , methods and criteria for inspection inspection practice at shop floor equipment overall inspection and review A brief test to gauge operator’s understanding

85. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Overall Inspection – Conduct inspection After completing education program, operator thoroughly inspect equipment category by category as per inspection checklist. As for example, on fastener inspection, need to make sure no corroded, no loose or no bent nuts and bolts. On electrical inspection, no scratched, bent or loose cable, no burn out lamp, no dirt/dust on control panel, etc. Then operator apply fuguai tags at : Need to identify also on any source of contamination and possible Kaizen activities. deteriorated component defective parts difficult inspection areas any abnormalities found.

86. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Overall Inspection – AM group meeting After thorough inspection, the brainstorming session should be held to review all the issues arise. The list of the fuguai , sources of contamination, difficult areas, and possible Kaizen should be readily available. Root cause analysis involving fish-bone diagram and WHY-WHY analysis need to be performed. The best solution should be selected for implementation. For Red fuguai tags, the AM members may propose the solution to Maintenance based on the analysis.

87. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Overall Inspection – Rectify equipment defect Operator will rectify any blue fuguai and Maintenance will take care of the red one. For sources of contamination and difficult inspection areas, operator or maintenance should in-charge it based on the skill and capability. Any Kaizen to improve inspection time target or reduce 6 big losses should be implemented. All the actions taken need to be verified for effectiveness and the same cycle should be repeated if corrective actions failed.

88. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Finishing – Tentative inspection standard During conducting overall inspection, operator determine specific areas of equipment for routine inspection based on inspection check sheet. Then tentative overall inspection standard can be set for routine inspection based on the inspection result. The standard should consists of: inspection methods inspection tools inspection time targets PIC safety concerns.

89. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Example of Tentative Overall Inspection Standard (by Categories)

90. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Finishing – Inspection skill matrix Operator skill matrix on overall inspection must be updated in order to identify which member is still need further training. Only trained operator will be allowed to carry out routine inspection as this operator has developed the ability of “technical sixth-sense”. The fully trained operators may also train their peers, so as will reduce group leaders burden. Any new member who join the group in the middle of program, need to be trained for the previous steps and skills in order to make them competent with their overall tasks.

91. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD HOW TO DEVELOP AN OVERALL INSPECTION Finishing – Review standard The overall inspection tentative standard should be review after improvement done on equipment. Especially on difficult inspection areas, when inspecting method or equipment were improved, the inspection time and method should be revised accordingly. This process should be repeated using CAPD method until a targeted inspection time is achieved. At the end, by repeating the process, operator’s skill will be enhanced and equipment fuguai and deterioration will be minimized or eliminated.

92. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD DELIVERABLES OOE Chart (AFTER) AM Kaizen Inspection checklist all category Inspection manual for all category Training materials and schedules Member skill matrix Inspection Time Reduction Chart Fuguai Detection (all category) Record of Difficult area to do inspection Record of Sources of contamination Tentative overall inspection standard.

93. AUTONOMOUS MAINTENANCE - STEP 4 OVERALL INSPECTION STANDARD DELIVERABLES OOE Chart (AFTER) AM Kaizen Inspection checklist all category Inspection manual for all category Training materials and schedules Member skill matrix Inspection Time Reduction Chart Fuguai Detection (all category) Record of Difficult area to do inspection Record of Sources of contamination Tentative overall inspection standard.

94. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN Major activities are :- Set autonomous maintenance standards and schedule by comparing standards prepared by operator & Maintenance to avoid overlap tasks. Religiously conduct routine maintenance in accordance with the standards. Move forward to achieve Zero Breakdowns by continuous improvement.

95. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN General Objective is to achieve :- The aims from the equipment perspective is to :- Continuously improve on equipment Totally review visual control Highly reliable equipment for operability & maintainability. Orderly shop floor realization. The aims from the human perspective is to :- Understand equipment as a total system. Establish autonomous supervision system Further develop ability to detect fuguai . ZERO BREAKDOWN

96. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN ZERO BREAKDOWN – FIVE COUNTERMEASURES 1. Establish basic equipment condition Clean equipment – rectify source of contamination. Tighten fasteners – prevent fasteners from loosening. Lubricate properly – identify lubrication points and surfaces. Improve equipment and work methods. Rectify difficult work area. Set and follow cleaning and lubricating standards.

97. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN ZERO BREAKDOWN – FIVE COUNTERMEASURES 2. Comply to proper usage of equipment Identify design condition of produced parts and vendors’ instruction manual. Standardize design conditions. Set and improve usage conditions of equipment. Properly install equipment. Prepare accurate operating procedures for production department reference. Always comply to the operating conditions and procedure.

98. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN ZERO BREAKDOWN – FIVE COUNTERMEASURES 3. Rectify deteriorated parts Determine category for overall inspection. Execute inspection training and practice for operators. Conduct overall inspection. Set and follow routine inspection standards. Monitor MTBF after routine inspection. Review intervals for parts replacement and overhaul. Monitor equipment condition for further improvement.

99. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN ZERO BREAKDOWN – FIVE COUNTERMEASURES 4. Correct design weakness Analyze and rectify condition of equipment. Improve equipment to extend life time on: structure and mechanism shape and material dimensional accuracy assembling accuracy resistance to corrosion and erosion strength etc.

100. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN ZERO BREAKDOWN – FIVE COUNTERMEASURES 5. Enhance maintenance & operation skills Enhance operation skill: Enhance maintenance skill: analyze service mistakes & countermeasure improve equipment assembly & dis-assembly establish spare parts control install poka-yoke apply visual control standardize procedure. analyze fuguai occurrence & countermeasure install poka-yoke apply visual control standardize procedure.

101. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN ZERO BREAKDOWN – FIVE COUNTERMEASURES 5. Enhance maintenance & operation skills Enhance operation skill: Enhance maintenance skill: analyze service mistakes & countermeasure improve equipment assembly & dis-assembly establish spare parts control install poka-yoke apply visual control standardize procedure. analyze fuguai occurrence & countermeasure install poka-yoke apply visual control standardize procedure.

102. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN FINISHING EQUIPMENT ACTIVITIES Review outstanding issues Step 1 to Step 5 are focused on matters relating to equipment and Step 6 will focus on quality matters. In some cases due to production can not stop, many issues remain unresolved. AM group need to revise the schedule to solve all the issues related to equipment and do not proceed to Step 6 yet. Unresolved issues should be focused on: equipment deterioration sources of contamination difficult work areas time target to achieve standards

103. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN FINISHING EQUIPMENT ACTIVITIES Obtain total equipment knowledge Knowledge on equipment as an integrated system. Final phase of education involves entire activities for equipment from Step 1 to Step 5. The understanding and practices on related activities such as cleaning, lubricating, fastening, setting, adjusting and routine inspection and maintenance. Assessment need to be done on each operators’ skills in reference to skill chart. The incompetent operators need to upgrade to reach required level of skill.

104. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN FINISHING EQUIPMENT ACTIVITIES Develop “technical six-sense” It is impossible to achieve complete inspection on equipment due to huge number of parts built in. It’s important to detect sign of abnormality, but with limited skill operator only able to detect exterior deterioration. In order to develop “technical six-sense” with the ability to detect interior sign of defective parts without disassembly, routine training must be conducted on below considerations: any indication of one breakdown? is the indication exist before breakdown? why indication not detected before breakdown? how to detect the indication? how to train operator on the indication detection?

105. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN FINISHING EQUIPMENT ACTIVITIES Review visual controls Step 4 outlined education and practice on overall inspection activity which increase operator technical knowledge and skills. With higher skills, operator need to check and evaluate the visual control implemented before. The corrective actions should be in place for any inadequate, neglected or unused visual controls. To further improve, operator need to search for new visual control methods.

106. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN FINISHING EQUIPMENT ACTIVITIES Tasks allocation The maintenance department need to prepare maintenance inspection standard before start Step 5. The standard should has schedules on inspection, calibration, parts replacement, monitoring, overhaul, etc. The overall inspection standard which prepared by operator in Step 4 need to compared with maintenance inspection standard item by item for each equipment. The two standards need to be reviewed for duplicated or omitted inspection items and allocation of routine tasks. It is important to adjust these two standards to become complement to each other.

107. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN FINISHING EQUIPMENT ACTIVITIES Example of Inspection Standard prepared by Maintenance Department (left side)

108. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN FINISHING EQUIPMENT ACTIVITIES Example of Inspection Standard prepared by Maintenance Department (right side)

109. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN Inspection items and intervals Inspection items for AM group are derived from tasks allocation by comparing standards previously. For inspection interval, it is advisable to minimize the inspection items for daily routine to items that will resulted in severe troubles in terms of safety and quality. To create best case, operator can perform inspection on daily routine interval without referring to check sheet. Only items on weekly and monthly, need to use check sheet. It is better to inspect more items in longer interval rather than less items in shorter interval. For example, 15 minutes monthly better than 2 minutes daily. ROUTINE INSPECTION BY AM TEAM

110. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN Inspection time In reality, the time given for inspection is extracted from operator’s work hours. The tentative time target is estimated base on following: After time target is set, trial of inspection need to be carried out. By improving inspecting methods, review intervals and allocation of tasks optimal combination for the standard can be achieved. what is the nature of operator’s normal task? how many machine operator operates? any allowances in inventory? is equipment automated? inspection during up or down time? ROUTINE INSPECTION BY AM TEAM

111. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Review Cleaning and Lubricating Standards Review Tentative Inspection Standards Compare with Maintenance Dept’s Inspection Standard Deliverable in Step 3 The Procedure 1. Review the standards. Deliverable in Step 4 Maintenance Dept prepared Standard prior to Step 5

112. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Set Tentative Autonomous Maintenance Standards Rectify Fuguai to improve standard Establish Autonomous Maintenance Standard Combine the standards The Procedure 2. Set the standard. Finalize the standards Improve the standards

113. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Review Cleaning & Lubricating Standards Based on experiences in Step 3, cleaning tasks and lubricating control need to be reviewed and necessary corrective actions should be in place. For cleaning standards : Are areas to be cleaned, methods, intervals and criteria for cleaning adequately covered? Do any sources of contamination unresolved yet? Are there any new sources of contamination detected? If any problem is found, perform corrective action.

114. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Review Cleaning & Lubricating Standards For lubricating standards : Are matters such as lubricating points & surfaces, types of lubricants, methods & intervals, and inspection criteria adequately covered? Is the allocating of lubricating tasks between Autonomous Maintenance and Maintenance Department adequate? If any problem is found, perform corrective action.

115. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Review Tentative Inspection Standards Based on experiences in Step 4, tentative routine inspecting standard need to be reviewed and necessary corrective actions should be in place. For each category of standards, items to review: Are the matters such as inspection location and objective clearly understood by operator? Are the inspection methods, intervals and evaluation criteria adequately covered? Are the inspection category suitable or necessary?

116. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Compare with Maintenance Depart. Inspection Standard Compare the two inspection standards : Determine a suitable allocation of inspecting tasks between Maintenance Department & Autonomous Maintenance group. Then combine inspecting standards for each category into a single routine inspection standard for every equipment.

117. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Set Tentative Autonomous Maintenance Standard Combine two standards to become tentative autonomous maintenance standard : Compile into one tentative standard in routine cleaning, lubricating and inspecting. 1. Single routine inspection standard - after comparing with maintenance standard and combine each category into one. 2. Cleaning and lubricating standard. - prepared during Step 3.

118. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Rectify Fuguai (external & internal) to improve Standard Carry out trial activity based on items in Autonomous Maintenance standard. Determine either tasks allocation between Maintenance Department and AM group is feasible to implement. Analyze phenomena of external and internal fuguai , breakdowns or minor stoppages based on structure and function of equipment and take corrective actions. Implement visual control and modify difficult work areas. Make assessment on operator’s skill and improve further .

119. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD The Best Practices Find the optimum tasks combination in term of combining cleaning, lubricating and inspecting into one or pair or triple tasks. Items to be considered during tasks combination: Decide the combine operator maintenance work sequences and routes by reviewing the sequences and routes in cleaning, lubricating and inspection as per Step 4. is the task for single or multiple operators? can operators carry tools in their hands? is the combination of routine tasks adequate?

120. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD The Best Practices Common items such as time frame, intervals, person in-charge and effective limit should be clearly indicated. It is advisable to prepare operator routine maintenance map and display instructive labels at equipment. The time spent on operator maintenance should be reduced compares to individual cleaning, lubricating and inspection as per example illustrated. Inspecting standards Category: Fastener, electrical, pneumatics, hydraulics, coolant Location: Parts, subassembly, equipment, process Criteria: Sample, reading of gauge, noise, vibration, overheat Method: Visual, touch, listen, smell, reading Countermeasure: Adjust, replace, tighten, call maintenance.

121. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Example of Time Target Reduction in Operator Maintenance

122. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Example of Autonomous Maintenance Standards

123. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Example of Autonomous Maintenance Standards (continued)

124. AUTONOMOUS MAINTENANCE - STEP 5 AM STANDARDS ZERO BREAKDOWN PREPARING THE AM STANDARD Example of Autonomous Maintenance Standards (continued)

125. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance What is meant by “Process Quality Assurance”? defined as : Any functional unit consists of a single or multiple equipment in production line which ensure confidence in producing good products. in short: Built-in quality

126. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance Major activities are :- Prevent outflow of defective products to next process. Prevent manufacturing of defective parts. Maintain process quality assurance Move forward to achieve Zero Defects by continuous improvement.

127. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance Major activities are :- Prevent outflow of defective products to next process. Prevent manufacturing of defective parts. Maintain process quality assurance Move forward to achieve Zero Defects by continuous improvement. General Objective is to achieve :- ZERO DEFECTS

128. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance The aims from the equipment perspective is to :- Assessment on process quality Assessment on quality condition Maintain reliable process to prevent outflow of defects Maintain reliable process to prevent manufacturing defects The aims from the human perspective is to :- Understand equipment condition relates to quality Achieve skill of autonomous supervision.

129. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance ZERO DEFECTS CHALLENGE Zero Defects is more difficult to achieve than Zero Breakdowns. Eliminating deterioration will reduce quality defects but not enough to achieve Zero Defects. The causes of quality defects have narrower tolerances and larger variation. Factors affecting quality in manufacturing product: accuracy, material & hardness for equipment physical property of raw materials positioning & machining methods operating conditions of equipment work method etc.

130. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance ZERO DEFECTS CHALLENGE Process Quality Assurance In manual operation, process quality is determined by human, methods and equipment , in that order. In automation operation, process quality is determined by equipment, methods and human , in that order. Automated process requires human to be knowledgeable to monitor equipment rather than manipulating equipment. Process quality assurance refers to proper maintenance of equipment or process on relationship between equipment condition and product quality to achieve Zero Defects.

131. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance ZERO DEFECTS CHALLENGE Nature of Quality Condition Equipment structure & subassemblies may affect products quality such as in: The above items involve certain conditions to achieve specified quality. This is called as “quality conditions”. Process quality assurance is equal with proper maintenance of quality conditions of equipment. shaft, bearing, hydraulics which rotate workpiece pins, datum, chuck, clamp which fix workpiece cutting tools & dies which cut workpiece temperature, pressure, molds as in molding machine

132. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance ZERO DEFECTS CHALLENGE Nature of Quality Condition Two approaches to achieve quality conditions: 1. Abstract approach 2. Concrete approach carried out by product design and engineering during engineering design stage. quality specification and conditions is determined based on future product analysis. carried out by production, maintenance and engineering during trial run stage. quality specification and conditions is determined based on actual observation.

133. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance ZERO DEFECTS CHALLENGE Nature of Quality Condition To reduce occurrence of defects, the quality condition should met the below criteria: Quantitative/clear Easy to set Constant Change is easy to detect Change is easy to restore

134. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance ZERO DEFECTS CHALLENGE Quality Specifications, Causes, Results. Quality specified by product design Working and operating conditions of equipment Quality of manufactured product Quality specification the detail of quality on material, shape, accuracy, thickness specified during engineering stage. Quality causes quality condition to manufacture product follow specification. the condition fixed to equipment during hands-over. Quality results refer to quality of product manufactured by equipment. maintain quality condition during mass production.

135. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance ZERO DEFECTS CHALLENGE Learn Quality Control Methods Operator need to understand on: Quality related items and methods : relationship between process quality and quality conditions corrective actions focused on quality results corrective actions focused on quality causes inspection items and criteria problem solving methods such as fish-bone diagram, WHY-WHY analysis etc 7 QC tools data collection procedure etc.

136. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance ZERO DEFECTS CHALLENGE Approach to Zero Defects There are three manufacturing approaches: Approaches to Zero Defects : Highly reliable process which no defect manufactured. Outflow of defects prevented by 100% automated inspection. Outflow of defects prevented by manual inspection. Develop activities to prevent outflow of defect parts to downstream process (focused on quality results) Develop activities to prevent manufacturing of defect parts (focused on quality causes) Develop activities to maintain quality conditions.

137. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Ideal manufacturing condition is highly reliable equipment to produce no defects or 100% automated inspection to prevent outflow of defects. Operator develop plan to tackle quality results first prior to quality causes due to complexity and difficulties. Preventive measures against outflow of defects to downstream process are developed. The below criteria are used on quality specification during manually prevent the outflow of defects : the specification is clearly defined the specification is well understood the specification is easy to observe the defect is easy to detect

138. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Prepare quality assurance flow diagram Assessment on process quality Preventive measures against outflow The Steps Detection of defects product Product handling

139. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Quality Assurance Flow Diagram (QAFD) Draw the flow diagram by arranging process quality as in quality control standards to the equipment as per example below. Casting m/c Milling m/c Drilling m/c Shrinkage, Bubbles Surface waviness Hole size visual +/- 10 micron 10.00+/-0.05mm

140. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Quality Assurance Flow Diagram (QAFD) Review inspecting items for each process quality to define who is responsible to do product inspection. If Quality staffs responsible, operator need to understand basic quality concept and visual control for parts handling. Quality product – product meets given quality standards Defect product – product does not meet given quality standards. Scrap – after evaluation, defects part need to scrap. (Red mark) Rework – after evaluation, defects part can be repaired. (Yellow mark) Hold – evaluation is still under progress. (Blue mark) Recycle – after evaluation, the part can be used. (Green mark)

141. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Assessment on Process Quality If operator responsible, review the quality inspecting items should be clearly defined in quality control standards. Operator must well understood on process quality for each of equipment. The inspecting items should be easily observed by operator either by visual or simple tools. Any defective parts can be detected at glance and early to prevent accumulative lost. The inspection methods, tools, visual controls and poka-yoke need to be in placed to achieve the above assessment.

142. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Preventive Measures Against Outflow Data collection need to be established in order to collect the data on outflow occurrences for at least the past 6 months. The following basic information need to be recorded & analyzed: Problem solving analysis need to be performed in order to get preventive measures on recurrences of outflow. process where the defects part was manufactured process where outflow of defects was detected type and details of defects concern on downstream process due to outflow difficulty level in detecting occurrence of defects possibility of outflow occurrence in future

143. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Preventive Measures Against Outflow The preventive measures could be established by classifying the occurrence of outflow into major indexes as follow: 1. Customer satisfaction 2. Frequency of occurrence critical dissatisfaction dissatisfaction complaint full satisfaction large number of defects with high risk in future moderate numbers of defects with high risk in future no defect but has potential to happen in future no defect but slight possibility to happen in future

144. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Preventive Measures Against Outflow 3. Possibility of outflow Ultimately, to prevent recurrence of same quality defects operator must correct equipment, working methods and working conditions (quality causes). no inspection gate, defects will definitely outflow visual or sampling inspection, high risk of outflow automated 100% inspection, low risk of outflow no defect produced, no outflow.

145. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Products Handling Review handling of defective products at each process and make assessment on the procedures to be clearly defined, well understood, easy to observe and easy to detect. Items involve: Review flow of quality products to downstream processes in same approach as above. The product handling standards and procedures need to be revised accordingly and key aim is to prevent confusion which impact downstream processes. location and method of storage work methods procedures

146. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY RESULTS Detection of Defects Product Verify remedies on quality result by confirm the below statement : If quality defects occurred : process or equipment automatically shutdown alarm lamp or warning sound or message display activated anyone able to detect defects product immediately. Quality defects are detected whenever they occurred

147. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES A series of activities to prevent the occurrence of quality defects by maintaining the quality conditions of equipment. The goal is to manufacture zero defects product. The methods are by identifying quality condition, accurate setting and prompt restoration. Problem solving method such as fish-bone diagram ad WHY-WHY analysis should be used to prepare the corrective actions. Then suitable visual controls and poka-yoke should be applied on tools, jigs or equipment to standardize the activities. Operator should be able to resolve issues on equipment quality conditions involving mechanical and visual nature.

148. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES Sequence of Countermeasures Good quality conditions must be provided by equipment rather than human being. The countermeasures taken should follow below sequences: Identify quality conditions Access quality conditions Remedy quality conditions Review and standardize

149. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES 1. Identify quality conditions Quality conditions which meet quality specifications need to be identify by categorizing equipment into detail sub-assembly to point out the condition of equipment that affect product quality. This initial preparation generally carried out by engineers from product design, engineering and quality assurance. As for example : Equipment : Assembly jig Quality spec : pin slanted (spec : +/-0.05 micron)

150. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES 1. Identify quality conditions Prepare equipment sub-assembly breakdown charts as below and identify quality conditions which affect pin slanted issue. Assembly jig Vertical Stopper Holder Horizontal Material Width Abrasion Bearing play Holder plate

151. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES 2. Assess quality conditions The quality conditions identified previously need to be assessed following the same criteria : The inspecting items on quality conditions need to be defined in quality control standards or preventive maintenance checklist. If the above criteria can not be achieved, the related equipment or tools need to be modified and/or use visual control aid. it is clearly defined it is well understood it is easy to observe it is easy to detect

152. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES 3. Remedy quality conditions The problem discovered need to be resolved accordingly using problem solving methodology to find root cause of the problems. Routine maintenance on quality conditions need to be defined to make sure the tools or equipment’s sub-assembly in optimum condition. Visual controls should be in placed to ease operator to detect any deterioration of quality conditions. In summary, Zero Defects are achieved through realization of highly reliable equipment, jigs and tools. The decision to modify equipment or not depend on cost effectiveness decided by management.

153. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES 3. Remedy quality conditions Example of quality conditions routine maintenance. (will put in standards later on) Assembly jig Vertical Stopper Holder Horizontal Material Width Abrasion Bearing play Holder plate Visual inspect Once/3 months Inspect: 1/M Lubricate: 1/2M Replace: 1/Y

154. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES 4. Review and Standardize The inspecting items for quality conditions need to be compiled and standardized as engineering procedures. The information need to be captured in procedures such as quality control standards and/or preventive maintenance checklist. Improvement done on remedies to quality causes will make some remedies on quality results unnecessary due to routine inspection and restoration of quality conditions. With present status, inspecting items in quality results need to be reviewed again and standardized.

155. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES Example of Quality Conditions Control

156. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES Departmental Activities Countermeasures on quality causes involve many department in the company such as engineering, product design, maintenance, production, quality assurance and so on. To achieve Zero Defects, quality causes not only investigated on equipment and tools alone but to other relevant factors such as: Raw material control Measuring apparatus control Jig and die control Machining condition control Mistake proof control

157. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance REMEDIES FOCUSED ON QUALITY CAUSES Departmental Activities For each category of control, operator need to perform same procedure as in countermeasures for equipment quality conditions. The below steps need to be implemented: The most difficult quality conditions of equipment is on machining conditions or parameter control. Separate machine parameter checklist should be displayed at machine. Identify quality conditions Assess quality conditions Remedy quality conditions Review and standardize

158. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance ESTABLISH PROCESS QUALITY ASSURANCE Review all numerous and diverse standards prepared in previous steps for : Standardize and applied the Quality Control Standards, Quality Conditions Standard, Preventive Maintenance Checklist and Machine Parameter Checklist in order to achieve: ZERO DEFECTS it is clearly defined it is well understood it is easy to observe it is easy to detect

159. AUTONOMOUS MAINTENANCE - STEP 6 Process Quality Assurance DELIVERABLES OOE Chart (AFTER) AM Kaizen Member skill matrix Preventive Maintenance Checklist Quality Conditions Control Quality Control Standards Machine Parameter Checklist

160. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision Major activities are :- Maintain current level of TPM. Improve current level of TPM. Passing on activity – hands over The aims from the equipment perspective is to :- Predict fuguai prior to occurrence Achieve Zero Accidents, Zero Defects and Zero Breakdowns Move forward to higher level of production technology The aims from the human perspective is to :- Establish self supervision on equipment. Detect and resolve problems independently.

161. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision MAINTAINING TPM LEVEL Operators consistently maintain basic equipment conditions and restore deteriorated parts. At the same time, maintenance staff provide effective planned maintenance by applying preventive maintenance. Operators conduct autonomous supervision follow the standards where any fuguai can be detected at glance. The main objective of Zero Accidents, Zero Defects and Zero Breakdowns can be achieved and TPM is being implemented. Progress of implementing Autonomous Maintenance will differ from 5 to 7 years depending on equipment. It is critical for management to keep the momentum especially when the key person was replaced.

162. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision MAINTAINING TPM LEVEL Move forward from Autonomous Maintenance is to maintain current level of TPM that was achieved, improve it and goes beyond it as per TPM development below:

163. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision MAINTAINING TPM LEVEL Maintaining Activity Autonomous Maintenance and Maintenance Department cooperate to maintain the TPM level established. Autonomous Maintenance inspect for equipment fuguai and deterioration and restore it to maintain basic equipment conditions. Maintenance Department enforce planned maintenance system to achieve high reliable equipment. Autonomous Maintenance and Maintenance Department must perform their assigned duties as specified in routine and periodic maintenance standards.

164. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision MAINTAINING TPM LEVEL Maintaining Activity The optimal routine servicing intervals can be established based on actual experience on cleaning, lubrication, inspection, condition monitoring, parts replacement , etc. The data and information obtained in maintenance activities can be used for future engineering development. It is important to has validity date on the standards established to make sure it is relevant at any time. Any changes or modifications on standards should be updated in order to make sure all people follow the same rules.

165. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision MAINTAINING TPM LEVEL Improving Activity Breakdowns and quality defects will be reduced with the implementation of TPM. Even though Zero Breakdowns and Zero Defects will never achieved, entire factory conditions will unbelievably improved. The Zero Breakdowns and Zero Defects are difficult to maintain throughout the years due to restriction on equipment conditions. The improvement plan to remedy or automate the processes, equipment, jigs, tools, work methods and other support systems should be in placed. Short term and long term plan should be available to implement continuous improvement as long as the company exists.

166. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision MAINTAINING TPM LEVEL Improving Activity The CAPD cycle approach is used to remedy problems. C A P D Check Action Plan Do

167. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision MAINTAINING TPM LEVEL Passing On Activity – Hands Over In any company, employees are always being replaced and the Autonomous Maintenance and TPM tends to be forgotten. As a result, the TPM system will collapse and the shopfloor will return to original conditions of not in order. It is not necessary to repeat the same journey of Autonomous Maintenance and TPM to newcomers. The newcomers need to be taught and trained with fundamental of TPM concept and Autonomous Maintenance steps.

168. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision MAINTAINING TPM LEVEL Passing On Activity – Hands Over The key methodology to sustain AM and TPM is by careful planning and systematically passed along to all levels in organization. Other activity is to hold AM/TPM day or week as awareness. The training need to be covered on : cleaning is inspection maintain basic equipment conditions fuguai detection and restoration sources of contamination difficult work areas Autonomous Maintenance steps

169. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM The goals of Autonomous Maintenance and TPM nearly achieved at this point of time. It depends on operating conditions and TPM policy but generally it has two dimensions : Infrequent equipment review Frequent equipment review What must be done next?

170. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM Infrequent Equipment Review Typically found in process industries such as petroleum, chemicals and cement. The processes are highly technical developed and the products have a long commodity life. Usually once constructed, it operated as long as possible until natural deterioration and aging with minor modifications such as parts replacement or upgrading instrument. For these industries, the current AM and TPM activities are sufficient enough but need to maintain the level of TPM. The most critical issue is the reduction of maintenance costs.

171. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM Frequent Equipment Review Typically found in assembly industries such as automotives, electronics and consumer goods. The processes are rapidly change due to short life cycle of the products. Once constructed, drastic and frequent model changes along with innovations in technology take place continuously. For these industries, the current AM and TPM activities are NOT enough and need to repeat on the new equipment. The most critical issue is the planning of AM activities for new equipment.

172. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM Apply TPM Experiences – Future Products Ideally AM and TPM is NOT NEEDED if: The scenario does not occur in reality Manufactures face heavy competition, thus need to realign their production technologies and products planning. product is easy to manufacture equipment is easy to operate equipment is properly maintained knowledgeable operator in equipment and quality.

173. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM Apply TPM Experiences – Future Products During engineering stage, it is difficult to eliminate cause of potential problems due to: These situations will result in: difficult to operate equipment difficult to manufacture product difficult to maintain equipment. factory engineer only understand drawings and catalogs product engineer understood nothing about equipment operator posses insufficient skills and knowledge.

174. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM Apply TPM Experiences – Future Products With aiming to higher level of TPM, the difficulties faced as mentioned earlier need to be reduced by: Operator sharing experiences in AM on equipment and products during design review. Maintenance staff offering ideas in a design review during engineering stage. Design and Engineering department involve in eliminating the Six Big Losses Various departments participate in the Autonomous Maintenance audits.

175. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM Apply TPM Experiences – Future Products This kind of efforts which involve all employees, activities to assure process quality are developed in which easy to manufacture product and easy to operate and maintain equipment are realized for the first time .

176. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM What must be done next? Step 7 focused on maintaining and improving the current level of TPM by establishing self-supervision on equipment and products quality. This can be achieved by rigorously following all the standards which has been set up earlier. After finished Step 7, two major activities remain: Automation Computerization

177. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM Automation It is considered as second industrial revolution started on early 1970s, the objectives are: To free human being from repetitive manual works To improve quality of products To reduce cost of products The next generation of TPM is to repeat CAPD cycle on labor intensive works to automated jobs by considering: easy to operate automated equipment easy to maintain automated equipment defect free product

178. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision AIMING AT HIGHER LEVEL OF TPM Computerization The first generation of TPM focused only on equipment and materials. The next generation of TPM focused on information flow. The flow of information is managed by computer and it’s called computerization. The CAPD cycle need to be used in defining the requirement on information flow for computerization in order to ensure optimal interfaces and flows of information among relevant departments.

179. AUTONOMOUS MAINTENANCE - STEP 7 Autonomous Supervision DELIVERABLES OOE Chart (AFTER) AM Kaizen Member skill matrix Training Plan for Newcomers Fuguai Prediction List Improvement Activity List Lesson Learned

180. Thank You