TPM Book. 4.Autonomous Maintenance

(c) “TPM in Process Industries”. Edited by Tokutaro Suzuki

1. Developing an Autonomous Maintenance Program

Autonomous Maintenance is maintenance performed by production department. Two keys of successfull Autonomous Maintenance Program are thoroughness and continuity. Goals: prevent equipment deterioration though correct operation and daily checks, bring equipment to its ideal state through restoration and proper management, establish the basic conditions needed to keep equipment well-maintained.

2. Production and Maintenance are Inseparable

3. Classifying and Allocating Maintenance Tasks

Maintenance Techniques: normal operation, preventive maintenance, predictive maintenance, breakdown maintenance. Activities of Production Department: preventing deterioration, measuring deterioration, predicting deterioration. 

4. Establishing Basic Equipment Conditions

Natural deterioration – Extend lifetime – Corrective maintenance

Accelerated deterioration – Eliminate causes – Establishment of basic conditions

5. Implementing Autonomous Maintenance Program Step-by-Step

  1. Perform initial cleaning
  2. Address contamination sources and inaccesible places
  3. Establish cleaning and checking standards
  4. Conduct general equipment inspection
  5. Perform general process inspection
  6. Systematic autonomous maintenance
  7. Practice full self-management

6. Preparing Autonomous Maintenance Master Plan

Prioritize activities by evaluating equipment, determine important elements. 

Equipment evaluation criteria:

  • Safety and environmental pollution
  • Quality and Yield
  • Working (operating status)
  • Delay factor (opportunity cost)
  • Period (failure interval)
  • Maintainability

7. Autonomous Maintenance Audit – must be done

to be continued…

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