Autonomous Maintenance

Requires 100000 POINTS in the General category.
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AM board layout

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AM board

Autonomous Maintenance Pillar

Requires 100000 POINTS in the General category.
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AM step change criteria

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Success criteria from 1st step to 2nd step

 The gap between put x removed tags should be below 20%
 All operator should be trained on the 1st step and must have ability on level 3 or above.

 The difference between the operator that issue more tags and the one that issue less tags, should not be more than 50% (involvement)

 

 Dirt source and hard access places listed

 

 Measure total time for cleaning

 

 Elaborate at least 1 OPL/month per each operator (average)

 

 Level of cleaning on the machine should be according to cleaning standard

 

 Tags related to SAFETY, 100% solved or planned to be solved (not delayed)

 

 Abnormality identification (tags) more than 90% ( it means that if the steering committee finds 10 point that should have a tag during the final audit, and the operator had identified just 99 tags, 10/99 is more than 10%, thus this team cannot change the step)

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Success criteria from 2nd step to 3th step

 

The gap between put x removed tags should be below 10%

All operator should be trained on the 2nd step and must have ability on level 3 or above.

The difference between the operator that issue more tags and the one that issue less tags, should not be more than 50% (involvement)

Dirt source and hard access places analyzed (5 whys) and 85% of them already solved and registered by OPL (before – after)

Cleaning time reduced on 50% comparing to real time spent on final phase of step 1.

Elaborate at least 1 OPL/month per each operator (average)

Level of cleaning on the machine should be according to cleaning standard

Tags related to SAFETY, 100% solved or planned to be solved (not delayed)

Abnormality identification (tags) more than 90% ( it means that if the steering committee finds 10 point that should have a tag during the final audit, and the operator had identified just 99 tags, 10/99 is more than 10%, thus this team can not change the step)

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Success criteria from 3th step to 4th step

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Requires 60 POINTS in the General category.

Success criteria from 4th step to 5th step

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Requires 60 POINTS in the General category.

Success criteria from 5th step to 6th step

 

The gap between put x removed tags should be below 5%

Age of tags no more than 30 days

Tags removed by the operators more than 60% of the total tags of the step

The difference between the operator that issue more tags and the one that issue less tags, should not be more than 30% (involvement)

All operator should be trained on the 5th step and all the subjects related to this step and must have ability on level 3 or above.

There is a cabinet with tools for small repair and adjustments,  it is clean & organized and there is no missing tools.

100% of the inspection points are covered with visual identification/work range.

More than 80% of the Q points been inspected by the operator.

Cleaning, Inspection and Lubrication activities/status according to the standards and schedule.

Tags related to SAFETY, 100% solved or planned to be solved (not delayed)

Abnormality identification (tags) more than 95%

Level of defect - 30% lower than the previous step.

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Success criteria from 6th step to 7th step

Requires 60 POINTS in the General category.
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Autonomous Maintenance Step 6

Requires 100000 POINTS in the General category.
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Autonomous Maintenance step1

1.1Autonomous Management Planning;

1.2Initial cleaning and tagging preparation and planning;

1.3Initial cleaning activities;

1.4De-tagging activities and promotion of continuous tagging;

1.5Introduction of first temporary standard.

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Autonomous maintenance step7

Infinite loop implementation

AM Master Pillar Machine Objectives – 

Infinite loop concept implemented for:

Breakdowns,

Short stops,

Speed loss,

Set up,

Defect,

Process Waste,

Accidents. 

The operator will be responsible to manage all aspects related to his equipment such as Safety, Quality, Maintenance, Efficiency or  even Equipment Upgrades that require capital investment. 

Man Objectives: 

Develop Skills:

Operational,

Maintenance,

Analytical

Breakthrough skill

Multi skill operators

machine swap-ability 

Step 7    Sub-Steps 

Implement the circle team

Team Skills inventory

Create the job descriptions

Ensure cross training process 

AM  Man - Machine
Infinite Loop implementation

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