What is Autonomous Maintenance?

Autonomous Maintenance

The concept of Autonomous Maintenance has acquired substantial popularity in the ever-changing world of industrial operations. AM is a proactive maintenance technique that encourages operators to take ownership of equipment care and preventative maintenance. It is a critical component of Total Productive Maintenance (TPM), a complete technique to increase equipment effectiveness while reducing downtime. Purpose Upskilling the operator/Self-initiated maintenance Steps

1. 1. Initial Cleaning
   2. Countermeasures for above highlighted problems
   3. Tentative Standardization
   4. General Training of Operators.
   5. Regularly or frequent basis checks/Inspection
   6. Workplace management
   7. Continuous improvement

Initial Cleaning– Clean the equipment thoroughly to detect and remove dirt, dust, and debris. Cleaning is Inspection- Cleaning with five senses

1. 1. See-Broken Elements, Heat Damaged Components, Rust, Dust, Dirt, Melted Components, Stains, etc.

1. 1. Touch– Rough surfaces, flaking paint, vibration, loose links, etc.

1. 1. Smell– Nontoxic oils, overheated motors or relays, etc.

1. 1. Hear-failing motors, worn moving parts, bearings leaking air, out-of-balance rotating parts, etc.

1. 1. Taste– Leaking Nitric acid bottle, airborne vapors, etc

Countermeasures This study aims to identify the fundamental factors contributing to equipment difficulties and devise effective solutions to mitigate their recurrence.

1. 1. Make Easier cleaning
   2. Reduce the scope of oiling to the minimum area
   3. Reduce the source of dirt, dust
   4. Reduce the mechanism of preventing the dispersion of cut powder and cutting oil to a minimum.
   5. Control the area where cutting oil is flowing and the flow rate of cutting oil
   6. Make inspection easier
   7. Provide the inspection window for invisible parts
   8. Provide an oil gauge
   9. Modify the oiling inlet and outlet for easier supply of oil
   10. Wiring to be organized
   11. Modify to make the exchange of parts convenient

How to take Countermeasures? Analyze on the basis of 5-Why to eliminate the root cause. Then apply kaizens for continuous improvements in quality circles etc. Tentative Standardization– Standardize the activities of cleaning, oiling, and others to maintain the Ideal State. The implementation of defined protocols for cleaning and fundamental maintenance should be established. Standardization

• • Machines: Pre-operational check sheets

• • Molds/Dies: Changeover criteria and inspections — Measuring Tools: Inspection with calibration (Inspection and Calibration) — QA Devices: Inspection and calibration of jigs

Operator Training and Education Operator training and education are the most important steps that enhance knowledge about equipment and machines, the basic functions of the equipment, how it works, etc. After this step, move on to evaluate them. At the end, confirm the competency. How to upskill the Operator?

1. 1. Give them an increased feeling of ownership
   2. Teach them about the basic process of the equipment
   3. Teach them the potential hazards
   4. Teach them What and Where to clean
   5. Teach them how to carry out a risk assessment
   6. Teach them the Importance of Cleaning
   7. Teach them how to handle minor failures
   8. Teach them the importance of Maintenance
   9. Teach them How to fill out documents

Regular Checks and Inspection– It is important to promote and encourage operators to consistently perform routine equipment checks. For regular inspection, regular cleaning must be done. Perform checks of Machines before starting day working/shifts, when resuming the operation; Frequency can be defined by the person in charge or Production/Maintenance Engineer etc. (Pre-Operational Check Sheets). Perform checks and inspection of Measuring Tools and Jigs prior to use, but perform periodically detailed cleaning and inspection(Inspection Sheet. Workplace Management– Sustaining, Managing, and Standardizing. The state and the method that needs to be followed are to be clearly established. It must be made clearly transparent as to why it needs to be followed (why it should be followed and what will if it is not followed). •The person should be educated and made capable of following instructions or standards •Proper conditions or environment (time etc.) must be provided to make it possible to follow. Continuous Improvement– Ongoing effort to improve For continuous improvement evaluation, Make Kaizens, Train and educate the operators, It should be error-proof, Plan Do Check Action management cycle, and apply 5 Principles for data analysis and awards are the important parts of continuous improvement.