Autonomous Maintenance

Basic Equipment Care Webinar Series: Defect Elimination

Defect Elimination is the third and final recording from Marshall Institute's and facilitiesnet.com's webinar. Senior Consultant Mark Jolley delivered the webinar for Trade Press Media, the operators of facilitiesnet.com and Maintenance Solutions Magazine titled "7-Steps to Implementing Basic Equipment Care." The two previous posts covered the 7-Stepsand the 5S'.

Today we'll cover Defect Elimination.


Click the video image below to play the short recorded webinar snippet covering the main elements of defect elimination.

Basic Equipment Care Webinar Series: 5S

Marshall Institute senior consultant Mark Jolley delivered a webinar for Trade Press media, the operators of facilitiesnet.com and maintenance solutions magazine titled "7-Steps to implementing basic equipment care". in the last post we covered the defect elimInation (hyperlink to previous post)

Today we'll cover 5S:

  • Sort
  • Set in Order
  • Shine
  • Standardize
  • Sustain

Click the video image below to play the short recorded webinar snippet covering the main elements of 5S

Basic Equipment Care Webinar Series: 7 Steps To Effective BEC

Marshall Institute senior consultant Mark Jolley delivered a webinar for Trade Press media, the operators of facilitiesnet.com and maintenance solutions magazine titled "7-Steps to Implementing Basic Equipment Care".

In three blog posts we'll release 3 recorded short snippets from the webinar:

  • 7 steps to BEC
  • Defect elimination
  • 5S

Today we'll cover 7 Steps to BEC:

1.) Perform Initial Cleaning
2.) Address Contamination Sources
3.) Establish Cleaning & Lubrication Standards
4.) Inspect Equipment
5.) Improve Process Knowledge
6.) Improve Workplace Organization
7.) Sustain Basic Equipment Care

Tidy Up Your TPM

Fall is in the air. The nights are getting cooler, the days are getting shorter, and the leaves are starting to change colors here in the Mountains of North Carolina. Fall has always been my favorite season for many reasons; including, Friday night High School football games, County fairs, church BBQ’s and most of all deer season!

Fall is also a great time to re-evaluate your TPM/TPR processes. To help self-evaluate your processes ask yourself these key questions:

Total Process Reliability: Going Beyond TPM

What is Total Process Reliability—“TPR” ?

Total Process Reliability (TPR) is an organizational approach to improving operational reliability of major assets; in-turn improving overall equipment effectiveness (OEE), increasing production capacity, reducing costs and growing the effectiveness of the relationship between maintenance and operations. TPR combines the proven tools and techniques of Total Productive Maintenance (TPM) with an effective organizational change model to establish a vigorous and structured improvement process leading to operational excellence. 

True TPR is philosophy adopted and practiced across the organization; it is NOT just a maintenance initiative.

Cars as an example of Basic Equipment Care

When we consider the Total Productive Maintenance process, specifically operator care, it is often helpful to use the analogy of how we should maintain our vehicle.  Car MaintenanceThe operator of the vehicle has certain responsibilities that if neglected will result in lower performance and possible catastrophic loss.  Clearly the operator has the responsibility to maintain fluid levels (gas, oil...), proper tire pressure, cleanliness of the vehicle, and report any abnormal noises, warning lights, or performance.  The operator does not need to be a mechanic, but does need to take ownership to ensure the proper service is performed.

Basically, the cost of maintaining equipment is directly correlated to the experience, ownership, and knowledge of the operator.  If you wish to test this theory, hand your car keys to your 17 year old son!! When my son was 17, even with repeated warnings, he didn't learn not to follow the car in front of him so closely. He finally learned the lesson when I got to buy a shiny new hood and bumper for my car. 

Autonomous Maintenance: Make it Visual

 

Visual controls are a great way to promote autonomous maintenance practices - an essential element ofTotal Productive Maintenance (TPM).

If you haven't done this already consider marking site-windows and pressure gauges so that the optimum operating range is clearly defined. This should 

be done in a way so that even an untrained operator can easily identify the gauge and determine if it is operating within the optimal ranges.

Valves should be marked “normal open” or “normal closed” clearly identifying the position of the valves under normal operating conditions