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How can you implement Autonomous Maintenance in your plant?

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Autonomous Maintenance (AM) is one of the eight pillars of Total Productive Maintenance (TPM), a systematic approach to improve equipment reliability and performance. AM empowers operators to take care of their own machines and perform basic tasks such as cleaning, lubricating, inspecting, and adjusting. By implementing AM in your plant, you can reduce breakdowns, defects, accidents, and waste, as well as increase productivity, quality, safety, and morale. In this article, you will learn how to implement AM in your plant in six steps.

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Malvi Parmar

Electrical Engineer|Documentation|Automations|Maintenance
Rajeev Bhandari

Plant Maintenance Manager at NAGATA AUTO ENGINEERING INDIA PRIVATE LIMITED
Jose Cano Ore

Supervisor de mantenimiento en Grupo Cantol

1 Assess the current situation

The first step is to assess the current situation of your equipment and operators. You need to identify the problems, causes, and effects of poor maintenance, such as dirt, dust, oil leaks, loose bolts, worn parts, and abnormal noises. You also need to evaluate the skills and knowledge of your operators, and their level of involvement and responsibility in maintenance activities. You can use tools such as checklists, audits, and surveys to collect data and analyze the gaps.

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Boris A.

Electricista Industrial, Electrónico orientado a las Telecomunicaciones, Especialista Autómata Industrial.
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Realizar charlas de operación y seguridad diaria en la planta, dar conocimientos de operación y mantención preventiva que no involucre riesgos al trabajador, hacer procedimientos de trabajo previos antes de empezar la labor, limpieza en el área, check list de máquinas, etc.

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2 Train and educate the operators

The second step is to train and educate the operators on the basic principles and practices of AM. You need to explain the benefits and goals of AM, and how it relates to TPM and other improvement initiatives. You also need to teach the operators how to perform the AM tasks, such as how to clean, lubricate, inspect, and adjust their machines, and how to use the tools and equipment safely and correctly. You can use methods such as lectures, demonstrations, simulations, and on-the-job training to deliver the training and education.

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Jose Cano Ore

Supervisor de mantenimiento en Grupo Cantol
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La capacitación y entrenamiento en el mantenimiento autónomo es súper importante, y hacerlo periódicamente por la rotacion del personal nuevo mucho mejor

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3 Implement the initial cleaning

The third step is to implement the initial cleaning of the equipment and the work area. This is a one-time activity that involves removing all the dirt, dust, oil, grease, and other contaminants that can affect the performance and reliability of the machines. The initial cleaning also helps to reveal the hidden defects and abnormalities that need to be fixed or prevented. The operators should work in teams and follow a standard procedure to conduct the initial cleaning. They should also document and report their findings and actions.

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Malvi Parmar

Electrical Engineer|Documentation|Automations|Maintenance
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One thing that is helpful is the reason for the requirement of automation system, as it is not easy to implement, although it does improve the future process

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Rajeev Bhandari

Plant Maintenance Manager at NAGATA AUTO ENGINEERING INDIA PRIVATE LIMITED
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CLITA is a part of JH ( Jishu Hozen) in TPM First Pillor Cleaning Lubrication Inspection?? Tightening Analysis - Finding abnormalities and Implement corrective/ Prevention action from above activities

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Ditiya Bariya

22 years experience in maintenance and project manager in automotive industry
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Initial stages properly cleaning. Daily check sheet update. Proper instruction of mc operatior. Properly lubrication. Rootin check.

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Renato Rocha

Gest?o de Facilities | Gest?o de Contratos | Planejamento Programa??o e Controle da Manuten??o
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Implementar a manuten??o em uma fábrica requer uma abordagem sistemática e organizada: 1. **Avalia??o inicial:** 2. **Planejamento:** 3. **Prioriza??o:** 4. **Treinamento da equipe:** 5. **Estabelecimento de procedimentos:** 6. **Aquisi??o de pe?as sobressalentes:* 7. **Utiliza??o de tecnologia:** 8. **Registro e análise de dados:** 9. **Feedback e ajustes:**

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Fernando Gorosito

Técnico electricista y en refrigeración
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Una cosa que he visto es que no hay un sistema personalizable o que se adapte al 100% a los requisitos de cada cliente/empresa sino que es al revés. El que pueda crear un sistema adaptable será el que gane el mercado

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4 Establish the cleaning and inspection standards

The fourth step is to establish the cleaning and inspection standards for the equipment and the work area. These are the guidelines that specify how, when, and by whom the cleaning and inspection tasks should be performed. The standards should be based on the best practices and the lessons learned from the initial cleaning. They should also be visual, simple, and clear, and include pictures, diagrams, checklists, and labels. The standards should be displayed near the machines and reviewed regularly.

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5 Conduct the routine cleaning and inspection

The fifth step is to conduct the routine cleaning and inspection of the equipment and the work area. This is an ongoing activity that involves maintaining the cleanliness and functionality of the machines, and detecting and reporting any signs of deterioration or malfunction. The routine cleaning and inspection should be done by the operators as part of their daily work. They should follow the cleaning and inspection standards and use the appropriate tools and equipment. They should also record and communicate their results and feedback.

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6 Implement the continuous improvement

The sixth step is to implement the continuous improvement of the equipment and the operators. This is a proactive activity that involves finding and eliminating the root causes of the problems, and enhancing the performance and reliability of the machines. The continuous improvement also involves developing and upgrading the skills and knowledge of the operators, and increasing their autonomy and ownership in maintenance activities. The continuous improvement should be done by the operators in collaboration with the maintenance staff and the management. They should use tools such as problem-solving, kaizen, and suggestion systems to implement the continuous improvement.

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gulam moinuddin

Senior maintenance Engineer in Patil group, SAP Plant maintenance , preventive maintenance, Break down maintenance , Predective maintenance, Compresso, cooling tower, EOT Crane, Heavy machinery and equipment maintenance
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Implementation of improvement, kaizen this is meaning of continuous improvement we can use this method and ultimately change and implement the system.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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How can you implement Autonomous Maintenance in your plant?

1

2

3

4

5

6

7

1 Assess the current situation

2 Train and educate the operators

3 Implement the initial cleaning

4 Establish the cleaning and inspection standards

5 Conduct the routine cleaning and inspection

6 Implement the continuous improvement

7 Here’s what else to consider

Manufacturing

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How can you implement Autonomous Maintenance in your plant?

1

2

3

4

5

6

7

1 Assess the current situation

2 Train and educate the operators

3 Implement the initial cleaning

4 Establish the cleaning and inspection standards

5 Conduct the routine cleaning and inspection

6 Implement the continuous improvement

7 Here’s what else to consider

Manufacturing

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