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SDD: Total Productive Maintenance Rev 1: 2013 November 10
Page 1 of 22
SDD: Total Productive Maintenance Rev 1: 2013 November 10
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Contents
Introduction .............................................................................................................. 3
Step 2 – Eliminating the sources of contamination .............................................. 4
Aim of step 2 ......................................................................................................... 4
Preventing leaking, spilling, spraying and scattering of:............................... 5
Lubricants .......................................................................................................... 5
Improving the accessibility of places that are hard to: .................................. 5
Contamination analysis sheet ............................................................................. 9
Step 2 – Eliminating the sources of contamination – Machine ....................... 11
What can be observed from Figure 7? ........................................................... 11
Aim of Machine Mapping: ................................................................................... 11
Who is responsible? ........................................................................................ 12
The importance of eliminating the sources of contamination ........................ 14
Obstacles to eliminating the sources of contamination .................................. 15
Steps to countermeasure contamination .......................................................... 15
Detecting abnormalities - 5 senses ................................................................... 17
Monthly Cleaning, Inspection and Lubrication Chart ......................................... 19
Cleaning Time Record Sheet ............................................................................. 21
Aim: ................................................................................................................... 21
Who is responsible for the document? ......................................................... 21
Table of Figures...................................................................................................... 22
SDD: Total Productive Maintenance Rev 1: 2013 November 10
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Introduction
Management and operators should by now be familiar with Autonomous
Maintenance Step 0 and 1 which is part of the TPM approach covering 8 Pillars. The
next session will focus on Autonomous Maintenance Step 2 and 3 and will go into
more detail on how to approach and implement these steps successfully. Operators
will carry on with what have been learned during Step 0 and 1 to ensure the success
of the next steps.
It is important not to try and rush the implementation of these steps as it is very easy
to skip vital procedures or documentation that forms part of the process. That is why
there are a set methodology to follow for each and every step to ensure the
successful implementation of TPM.
Figure 1: Stepped Approach to TPM implementation for Autonomous Maintenance
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Step 2 – Eliminating the sources of contamination
Before starting with Autonomous Maintenance Step 2, Step 0 and 1 must be
implemented properly and operators must understand what are expected from them.
The best method of ensuring success is by conducting weekly audits to get
operators into a habit of doing the right thing automatically.
Aim of step 2
This step is designed to cut off sources of dust and stains, to improve places where
scattering prevention, cleaning and oiling are difficult and to enable cleaning and
oiling within the target time. Operators should strengthen their ability to improve
equipment and gain confidence to pursue even higher level improvements.
When referring to sources of contamination it includes everything identified during
step 1. In step 2 the focus is on eliminating the sources of contamination.
Operators maintain the equipment after Step 1 training and implementation, but quite
often the task just becomes intolerable and very time consuming. That is why step 2
is important to reduce the amount of time it takes for an operator to clean, inspect
and lubricate.
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We can only achieve a reduction in time by implementing the following methods:
Preventing leaking, spilling, spraying and scattering of:
• Products
Lubricants
• Hydraulic fluids
• Powders
• Vapours
• Other process materials and
Improving the accessibility of places that are hard to:
• Clean
• Check
• Lubricate
• Tighten
• Operate
• Adjust
How can leaking, spilling, spraying and scattering be prevented?
Answer: Implementing preventative measures to avoid material from leaking, spilling,
spraying and scattering.
These measures can include regular inspection of pipes, fittings, pumps and
reservoirs.
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Figure 2 below show an operator busy inspecting his equipment.
Figure 2: Operator inspects equipment
Attaching covers or guards to machines where material are likely to spray or
scatter.
Guards can range from a simple plug to a larger metal sheet. Drip trays can be used
in conjunction with guards to avoid oil, cutting fluid and other liquids from dripping
onto the floor.
Figure 3 below show a simple plug to eliminate debris from getting into the hole. This
simple measure save a large amount of time, especially when there are multiple
holes on a machine where dust can gather and collect.
SDD: Total Productive Maintenance Rev 1: 2013 November 10
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Figure 3: Example of a plug to eliminate contamination
.
Figure 4: Machine with guard attached
Transparent cover,
normally closed
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Providing and using the correct and proper tools to operate and maintain the best
machine condition. Operators tend to use tools that are readily available, if correct
tools are not provided or close to the point of use. An example is an operator using a
screwdriver to make a hole, instead of a punch or using a big wrench as a hammer.
Figure 4 below illustrates some tools and the appropriate warning to not use a tool if
it is not suitable for the task at hand.
.
Figure 5: Correct tools for the work required
Any improvement possible must be done to ensure high employee morale are
promoted and the final product reach the customer faster at a quality level that
satisfies the needs of such a customer.
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Contamination analysis sheet
Figure 6: Contamination Analysis example
Figure 6 is an example of a sheet that is used when a source of contamination have
been identified and also to classify into which category of TICL it belongs.
The sheet consist of a number of columns and rows that need to be completed.
Each section will be explained below.
Zone/Area: This section is where the area or zone on the machine are where the
contamination occur.
Equipment Name: What is the name of the piece of equipment or machine?
Preceding Process: What process immediately precedes the current process?
Control Number: That is a number that follows on from the previous contamination
analysis sheet.
Zone/Area Moulding
Equipment Name HWS
Preceding Process Sand plant
Control No
Rev
Date 08.04.2013
Clean Lubricate Inspect Access
Entire plant
During
operation of
the moulding
machines
001Dust Bentonite and
coal dust
Moulding
operation during
castingX X
Autonomous Maintenance Step 2 Contamination Analysis Sheet
Contamination/Obstr
uction DescriptionComposition Area on equipment where found
Source of
contamination
Hard to ( Yes No X ) Instance of
occurrenceKaizen control
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Revision: What is the revision number on that specific piece of equipment?
Date: Date the contamination was identified and classified.
Contamination Description: What type of contamination have been encountered.
Composition: Does the contamination consist of more than one type of material.
Area on equipment where found: Picture or description of where the contamination
occurs.
Source of Contamination: What is the source of the contamination? The operation or
process where it starts.
Hard to columns: Indicate using a green tick for yes and a red cross for no into which
category of TICL the contamination falls.
Instance of Occurrence: When does the contamination take place? During which
operation or when what actions are performed?
Kaizen Control: Are there a Kaizen sheet that is linked to the contamination?
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Step 2 – Eliminating the sources of contamination –
Machine
Figure 7: Machine mapping example
What can be observed from Figure 7?
The areas marked A, B and C indicates a number of chain driven gears and a screw
mechanism. These areas are visible because the metal covers are removed.
Under normal operating conditions the covers would be in place and it would be
extremely difficult and time consuming to inspect, clean, tighten and lubricate those
working parts of the machine.
Aim of Machine Mapping:
The aim of a machine mapping exercise are to identify all the areas on the machine
that are hard to clean, inspect, lubricate and tighten.
A
C
B
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Who is responsible?
Machine mapping are performed as a group to identify these difficult areas that have
been observed in Figure 7.
An experienced engineer should be chosen as the group leader to provide guidance
on what needs to be done.
Machine mapping can be used in conjunction with a red tag exercise to identify
problems and sources of contamination.
Access must be simplified to areas of the machine that needs to be inspected,
cleaned, tightened and lubricated.
This can be achieved by implementing some of the following solutions:
Hard guarding (wire mesh, etc.) is needed for safety, in many applications to protect
the operator or maintenance personnel from parts of the machine that are moving,
rotating, etc. They can be painted many colours, including safety yellow, but as can
be seen from figure 8 below it makes inspection extremely difficult.
Figure 8: Before
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A simple and fast sollution is painting the mesh black. This would allow the operator
to see through the mesh as per figure 9 below saving time and effort.
Figure 9: Black mesh simplify inspection
See through machine guards to eliminate swarf and coolant spraying is an effective
measure to ensure easy inspection and a reduction of cleaning time, because the
contamination are controlled and localised at a certain area.
Figure 10 below is an example of a see through machine guard.
Figure 10: Clear machine guards
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The importance of eliminating the sources of contamination
Sources of contamination must be eliminated because contaminants hide machine
defects that causes quality defects and breakdowns.
Common causes of contamination include:
Fibres from clothing and cloths (hair)
Excessive dust & dirt.
Water & coolant leaks.
Spillage due to missing or damaged guards, shields or chutes.
Damaged extraction.
Incorrect swarf removal.
Incorrect design of equipment.
Work method.
Incorrect tools/equipment to do the job
Some items are generated unavoidably due to the principles of processing and
cannot be stopped at the source.
The following steps should be taken:
Reduce absolute volume
Limit the volume of releasing agent
Limit the volume of coolant used
Reduce cutting margins
Cut scattering
Prevent scattering through minimum coverage of the relevant
location.
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Obstacles to eliminating the sources of contamination
Although the harmful effects of contamination are widespread, often little are done to
reduce the sources:
Most companies employ the use of ready-made machines, because custom build
equipment are very expensive. The reality is that large amounts of time, effort and
money can be saved by making practical modifications to equipment to simplify
cleaning and basic maintenance.
Steps to countermeasure contamination
The first step is to accurately determine the nature of contamination.
How and where are the contamination generated? A why-why analyses can be used
if the cause are difficult to determine.
The next step is to gather quantitative data(kg’s, litres, etc.) on the volume of leaks,
spills and other contamination (this helps operators understand the importance of
measurement).
Failure to apply a problem solving
technique to contamination sources
Operator and management
knowledge of the equipment basic
conditions
Lack of understanding of the process
Lack of knowledge of the correct operating
standards of the equipment (lubrication
levels, pressure etc)
No system to identify abnormalities (Daily
tagging and TICL)
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An oil leak for instance might look insignificant, but if the amount of lost oil are
measured and can be financially quantified, it can help the operator understand how
much money can be saved by identifying and reporting leaks.
Filter material to reduce dust.
Figure 11: Pump with filter
Figure 12: T-slots contamination eliminated
T slots filled in with plastic covers saves a 3 hour cleaning operation.
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Detecting abnormalities - 5 senses
Use the 5 senses, sight, sound, touch, smell and taste to identify abnormalities.
Operators should be trained by maintenance to identify these abnormalities.
Figure 11 below indicates how the 5 senses can be utilised.
Figure 13: The 5 Senses
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Figure 14: Inspection stickers
Figure 14 above is an example of inspection stickers that can be used to attach to a
certain part of the machine or a piece of equipment to assist the operator in using the
senses effectively in identifying abnormalities.
Any combination and number of inspection stickers can be utilsed, depending on the
type of equipment. Certain types of equipment could have more than one sticker like
an electric pump can have a sight, smell and hearing sticker. Look for smoke, smell
a burning smell or hear a noise could all be indicators
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Monthly Cleaning, Inspection and Lubrication Chart
Figure 15: Graph indicating reduction in time
Figure 15 is a simple graph to indicate the reduction in cleaning, inspection and
lubrication time after Step 2 of Autonomous Maintenance have been implemented.
Team leaders must be able to measure the time it takes operators to do TICL
actions.
Pro-active measures must be implemented to ensure that the TICL times are
reduced. Monthly awards for the cleanest machine or workstation can be a good
measure to encourage operators to clean the equipment thoroughly.
Making continuous improvements and training of operators ensure that TICL time
are reduced more and more each month.
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Figure 16: Cleaning Time Record Sheet
Step 1 Step 2 Step 3
Time (sec) 450 334 256
% Improvement 0% 26% 23%
CLEANING TIME REDUCTION SUMMARY SHEET
TPM IMPACT
STEP 1 - 3
Person Responsible
Reference Number
Team Leader
Team Leader Signature
Approval Date
TPM Champion Signature
450
334
256
0%
26%
23%
0
50
100
150
200
250
300
350
400
450
500
Step 1 Step 2 Step 3
Cleaning Time Reduction Table
% Improvement
Time (sec)
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Cleaning Time Record Sheet
Aim:
The aim of the cleaning time record sheet is to track the cleaning times on the
machines as a company moves from Step 1 to Step 3 of Autonomous Maintenance
to determine if there are any reduction in the amount of time it takes to perform the
TICL actions.
Who is responsible for the document?
Answer:
The team leader is responsible to generate the information that are required to
complete the form and to ensure sustainability. The team leader should receive
training regarding time study if required to ensure the accuracy of the sheet.
The TPM champion and team leader should also sign the document to acknowledge
that they agree with the times recorded for cleaning.
The team leader must ensure that the cleaning functions are timed and recorded
regularly to guarantee an accurate document.
The frequency should be daily during the kick off at each Autonomous Maintenance
step and can be gradually reduced to once a week if the operators are able to show
a higher level of understanding regarding the cleaning functions.
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Table of Figures Figure 1: Stepped Approach to TPM implementation for Autonomous Maintenance ....................... 3
Figure 2: Operator inspects equipment ................................................................................................. 6
Figure 3: Example of a plug to eliminate contamination ...................................................................... 7
Figure 4: Machine with guard attached ................................................................................................ 7
Figure 5: Correct tools for the work required ......................................................................................... 8
Figure 6: Contamination Analysis example ........................................................................................... 9
Figure 7: Machine mapping example .................................................................................................. 11
Figure 8: Before .................................................................................................................................... 12
Figure 9: Black mesh simplify inspection ............................................................................................. 13
Figure 10: Clear machine guards .......................................................................................................... 13
Figure 11: Pump with filter .................................................................................................................. 16
Figure 12: T-slots contamination eliminated ...................................................................................... 16
Figure 13: The 5 Senses ........................................................................................................................ 17
Figure 14: Inspection stickers ............................................................................................................... 18
Figure 15: Graph indicating reduction in time ...................................................................................... 19
Figure 16: Cleaning Time Record Sheet ............................................................................................... 20