Autonomous Maintenance Step 2

AM Step 2: Countermeasures for SOCs & HTAs

Objective: Countermeasures for SOCs and HTAs

Stated in other words:

Prevent causes of dust, dirt, and leakage
Improve places that are difficult to clean, inspect, and lubricate
Reduce the time required for cleaning, inspection, and lubrication

AM Step 2 Sub-sections

Step 2 Activities:

Countermeasures to SOCs
Countermeasures to HTAs
Implement Visual Controls

Sub-section 1: SOCs

Identify Source Of Contamination
Controllable vs. Uncontrollable contaminations
Eliminating for controllable contaminations
Create “Catch pan, localized covers” for uncontrollable contaminations.

Sub-section 2: HTAs

Identify Hard To reach Area
Countermeasures for HTAs
Visual Control

Sub-section 3: Breakdown Analysis

Methodology

AM Step 2.1 – Identify SOCs

Process:

Develop a list of SOCs if not complete from Step 1
Use the SOC List generated from the AM Step 1 “Four Lists” activity
Use F-Tags to continue to identify SOCs (Track them on F-Tag Centre)

AM Step 2.2 – Categorizing SOCs

Objective:

To Categorize the list of SOCs:
- Controllable vs. Uncontrollable (see next slide)
- Then as A, B, C priorities (High/Med/Low)
- Then follow the ECRS methodology (see next)
Use the SOC list from AM Step 1 and mark each SOC as A/B/C priority and Controllable vs. Uncontrollable

Controllable vs. Uncontrollable

Controllable:

These SOCs are within the team’s scope of control.

Uncontrollable:

These SOCs are outside the team’s scope of responsibility

NOTE: Work on Controllable SOCs first!

ECRS Methodology

Objective:

A quick method to develop countermeasures for SOCs & HTAs:
- Eliminate
- Combine
- Replace
- Simplify

ESCR is a tool to facilitate the development of countermeasures for SOCs. Ideally, all SOCs would be eliminated. At a minimum, SOCs are simplified.

ECRS Methodology Examples

ECRS:

Eliminate – outright removal of the SOC

Ex. Install a “No-dump” sensor for missing pouches

Combine – multiple SOCs into a single SOC

Ex. Combine the waste streams under the machine into a single catch-bin (vs. many today)

Replace – “Catch pan” to treat it easier

Ex. Specific catch pan for mix, noodles, etc to recycle them

Simplify – the time required to manage the SOC

Ex. Install “catch-bins” under Bartelts to collect spillage

Countermeasures for SOCs Form

A spreadsheet version of the form can be downloaded here

SOC PROBLEM

CARDBOARD CUT-OUTS FALL FROM MAGAZINE
DUST AND CUT-OUTS ACCUMULATE IN DIFFICULT TO ACCESS AREAS

Temporary SOLUTION

Place slip sheet under source to catch debris

SOC Countermeasure

Replace the temporary slip sheet with a stainless manufactured version
Design change – increase the angle and funneling down to a bucket

Benefits:

Reduces time to clean
Eliminate the use of compressed air, dust exposure

AM Step 2.3 – Controllable SOCs

For Controllable SOCs:

All Controllable SOCs should be Eliminated (ideal scenario)
In this step, we implement the countermeasures for Controllable SOCs first

AM Step 2.4- Identify HTAs

Process:

Develop a list of HTAs if not complete from Step 1
Use the HTA List generated from the AM Step 1 “Four Lists” activity
Use F-Tags to continue to identify HTAs (Track them on F-Tag Centre)

AM Step 2.5 – Eliminate HTAs

Objective:

Prioritize the list of HTA as A, B, C categories and then follow the ECRS methodology
Aim to eliminate the most critical (results-oriented) HTAs for cleaning, inspection, and lubrication

AM Step 2.6 – Visual Controls

Objective:

Implement Visual Controls for cleaning, inspection, and lubrication points

– eg. Mark the “green and red” zone on the gauges existing on the line

– eg. Mark the inspection point for a sheet of Lexan that was installed

Example of Visual Controls: Operating range in gauges

AM Step 2.7 – Temporary Standards

Objective:

Develop a temporary standard for Lubrication (very basic at this point)
Modify the temporary Cleaning standard that was developed from AM Step 1 considering the improvements generated after SOC and HTA countermeasures are in place.