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1 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530
Jidoka (human
automation)
Global Production System
Product/Patient Quantity Analysis
Kaizen Kaikuku
Just-in-Time
Measures
Standard
Operations
Heijunka
(Leveling)
Continuous
Flow
Total
Productive
Maintenance
Poka-yoke (mistake
proofing)
Kanban
Setup Reduction
Changeover
Multi-process
Operations
GPS
MUDA MUDA
Visual
Control
Andon
TAKT TIME ONE PIECE FLOW PULL PRODUCTION
R
e
d
e
p
l
o
y
m
e
n
t
Committed Leaders
Profit =
Price - Cost
TAKT Time Map
Capacity Tables
Cost Reduction By Eliminating Waste
GPS Depth Study
NVA/VA-
Functions/Mgrs
Quality Cost Delivery
Morale Safety
Value Stream Mapping
5S • Sorting
• Simplifying
• Sweeping
• Standardizing
• Self Discipline
3P Prod Prep
7 Flows Medicine
7
Wastes
RPIW
7 Flows
Factory
4 No’s
© 1996-2013, John Black and Associates LLC
(modified from Hiroyuki Hirano, Productivity Press).
Autonomous
Maintenance
Module 13
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 2
Autonomous Maintenance: Key Points
The four types of maintenance are:
1. Preventative maintenance.
2. Predictive maintenance.
3. Breakdown maintenance.
4. Autonomous maintenance.
Equipment operators share the responsibility for the
performance and health of their equipment.
Autonomous maintenance is an eight-step process.
3 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530
Equipment and Machines are an
Integral Part of Healthcare
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 4
Preventive Maintenance: Daily activities designed to
maintain basic equipment conditions.
Predictive Maintenance: Detects equipment deterioration
through condition-based analysis. Speed reduction,
vibration analysis, lubricant contamination, etc.
Breakdown Maintenance: Corrects equipment
deterioration after the occurrence of a breakdown.
Autonomous Maintenance: Equipment operators accept
and share responsibility with maintenance for the
performance of their equipment
Types of Maintenance
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 5
8 Steps to Implement Autonomous Maintenance
Energy Awareness
Establish a Baseline
Critical Cleaning is Inspecting
Eliminate Contamination and Simplify
Visual Management
Equipment Lubrication
Consumables
Equipment Maintenance
6 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530
To Establish the Baseline
Condition of a Used Car
• Check for body
damage.
• Look for leaks.
• Check tire wear.
• Vibration.
• Observe the gauges.
• Listen for vibrations
and noises.
• Check for unusual
odors.
7 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530
Establish a Baseline:
Determine the
Condition of your
Crash Cart
Is the cart free
of:
Dirt / Dust.
Faulty wheels.
Missing items.
Expired items.
Is the cart
difficult to:
Move.
Inspect.
Reach.
Clean.
Can you identify
the following?
Safety hazards.
Go-no-go points.
Items in need of
maintenance.
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 8
Q: Do you wash your car by hand or in a car
wash?
Cleaning is Inspecting
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 9
Simplify equipment for easy and safe cleaning,
inspection, and maintenance.
Simplify
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 10
EKG Machine
IV Pump Ask “Why?” five times.
What can the answers tell you?
You still have to take action!
The Five Whys
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 11
How would you know what the
normal operating range is?
How would you know if there
were problems developing?
Abnormal? Unknown? Normal?
12 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530
Mod 13 – Autonomous Maintenance
13 Autonomous Maintenance
v20130530 ©1996-2013, John Black and Associates LLC
Licensed Materials – USA Copyright Laws Apply 13
Autonomous Maintenance Summary
Autonomous Maintenance is a
partnership between equipment
operators and maintenance
personnel who share responsibility
for the performance and health of
the equipment.