Autonomous Maintenance

Course Outline

1. Introduction to Autonomous Maintenance
   • Overview of Total Productive Maintenance (TPM)
   • The role of AM within TPM
   • Benefits of AM for operators and organizations
2. Pillar 1: Operator's Role in Maintenance
   • Understanding equipment
   • Recognizing abnormalities
   • Basic maintenance tasks for operators
3. Pillar 2: Cleaning, Inspection, and Lubrication
   • Importance of cleaning and inspection
   • Techniques for effective equipment cleaning
   • Basic lubrication principles
4. Pillar 3: Setting Standards
   • Standardized cleaning and inspection routines
   • Checklists and documentation practices
5. Pillar 4: Eliminate Causes of Contamination and Hard-to-Access Areas
   • Identifying and addressing contamination sources
   • Modifications to improve accessibility
6. Pillar 5: Visual Management Techniques
   • Implementing visual cues for maintenance
   • Using labels, tags, and signs
7. Pillar 6: Skill Development and Operator Empowerment
   • Training operators in advanced maintenance techniques
   • Building confidence and ownership
8. Pillar 7: Continuous Improvement in AM
   • Leveraging Kaizen principles
   • Case studies and success stories
   • Metrics to measure AM performance
9. Hands-On Practical Sessions
   • Guided equipment cleaning and inspection exercises
   • Developing and implementing visual management tools
10. Assessment and Certification

• Final evaluation through written and practical assessments
• Certification of successful participants

Course Objectives

• Equip operators with the knowledge and skills required to perform basic maintenance tasks independently.
• Foster a sense of ownership and responsibility among operators for maintaining their equipment.
• Reduce equipment downtime, improve reliability, and minimize maintenance costs.
• Build a foundation for Total Productive Maintenance (TPM) practices within the organization.

Learning Outcomes

By the end of the course, participants will be able to:

1. Understand the principles and importance of Autonomous Maintenance within TPM.
2. Identify and address equipment abnormalities during routine operations.
3. Perform basic maintenance tasks such as cleaning, lubrication, and inspection.
4. Develop and implement standard operating procedures (SOPs) for maintenance tasks.
5. Use visual management tools to monitor and maintain equipment health.
6. Contribute to continuous improvement initiatives in maintenance practices.

Methodology

• Interactive Lectures: Theoretical sessions with multimedia presentations to explain key concepts.
• Workshops: Hands-on exercises to reinforce practical skills in equipment cleaning, lubrication, and inspection.
• Group Activities: Collaborative tasks like creating visual management tools or solving case studies.
• Simulations: Practice sessions using real or simulated equipment to build confidence.
• Assessments: Written tests and practical evaluations to gauge understanding and skill mastery.
• Coaching & Feedback: Personalized guidance from trainers during hands-on activities.
• Follow-up Support: Post-training resources like manuals, videos, and access to a mentor or expert.