AM Team Step 1

Initial Cleaning
It is very difficult to do several things at the same time. That’s why autonomous management training takes a step by step approach, making sure each key skill is thoroughly learned before going on to the next. Autonomous management is implemented in seven steps.

Step by step approach

It is very difficult to do several things at the same time. That’s why autonomous management training takes a step by step approach, making sure each key skill is thoroughly learned before going on to the next. Autonomous management is implemented in seven steps.

Step by step approach

Operator’s skill

The ability to detect, correct and prevent equipment abnormalities and make improvements.
This includes understanding the importance of:

• Cleaning, inspection and proper cleaning methods
• Improving the equipment to reduce source of dirt and prevents its accumulation and spread
• Improving the machine to facilitate inspection with visual management
• Improving the machine to facilitate access, therefore maintainability
• Proper lubrication, including lubrication methods and methods for checking lubrication
• Improving operation and maintenance procedures to prevent abnormalities and facilitate their prompt detection

1. The ability to detect, correct and prevent equipment abnormalities and make improvements.

2. The ability to understand equipment functions and mechanisms, and the ability to detect causes of abnormalities.

• Knowing what to look for when checking mechanisms
• Applying the proper criteria for judging abnormalities
• Understanding the relations between specific causes and abnormalities
• Knowing with confidence when the equipment needs to be shut off
• Being able to diagnose the cause of some types of failures

3. The ability to understand the relationship between equipment and quality, and the ability to predict problems in quality and detect their causes.

• Knowing how to solve a problem (e.g. breakdown, minor stoppage, material problem, material defect, etc.)
• Understanding the relationship between product quality characteristics and equipment mechanisms and functions
• Understanding tolerance ranges, how to measure them and how to avoid deterioration
• Understanding the causes of quality defects
4.The ability to understand why we lubricate and the consequences of a lack of CILT, and the ability to predict problems and detect their causes.

5. The ability to make repairs.

• Ability to replace parts
• Understanding of life expectancy of parts
• Ability to deduce the root causes of breakdowns and minor stoppages
• Ability to take emergency measures
• Ability to assist in overhaul repairs

Obviously, anyone who masters all these skills has achieved a very high level indeed, and no one is expected to do that quickly. Instead, each skill should be studied and practiced for whatever time it takes to acquire proficiency.
6.

What is AM?

It is the direct participation of production operators in the management of the machines through daily checks, lubrication, early detection of abnormalities, replacement of parts or small repairs
1. Purpose of AM

- The purpose of an Autonomous management program is threefold.
First, it brings production and maintenance people together to reach a common goal: to stabilize equipment conditions and stop accelerated deterioration. Operators learn to execute important daily tasks like cleaning, inspection, lubrication, quality checks and other light maintenance tasks like simple replacements and repairs.
- Second, the program is designed to train operators about how their equipment works, what common problems can occur and how these problems can be prevented by early detection and treatment of abnormal conditions.
Third, the program prepares operators to be active partners with maintenance and engineering personnel in improving the overall performance and reliability of equipment.
- In average 70% of the failures and of the downtime in the process and assembly industry, are caused by lack of proper cleaning, inspection, lubrication and tightening (CILT).

Traditionally the general attitude on the shop floor has been
“ I run it, you fix it”
Operators can easily prevent many breakdown, short stop, waste and quality problems by learning how to recognize abnormal conditions and how to link these abnormal conditions with losses.
By now it should be clear that this way of thinking does not promote optimal performance.
AM teaches production operators to understand their equipment. Equipment knowledge is no longer limited to how to produce, now it also include the following valuable skills:
The ability to ESTABLISH equipment conditions,
knowing how to distinguish between normal and abnormal conditions
The ability to MAINTAIN equipment conditions,
knowing how to ensure that normal equipment conditions are met
The ability to RESTORE equipment conditions,
knowing how to respond quickly to abnormalities
When operators have acquired these three skills, they will be understand the equipment well enough to recognize the causes of future problems. They will realize when the machine is about to produce defects or break down. They will also be able to respond quickly.