Autonomous Maintenance Step 4 Case Study

Implementation Team

Values:

• Integrity
  • Demand diversity of thought!
• Responsibility and accountability
  • Define & communicate roles, responsibilities, and actions plans for teams and individuals!

5W & 1H

• WHAT: Major Stoppages/Breakdowns
• WHEN: Daily
• WHERE: Packaging Lines
• WHO: Mechanic
• WHICH: N/A
• HOW: Not Enough time to Eliminate

SUMMARY OF PROBLEM:

Mechanics do not have enough time to Eliminate Major Stoppages/Breakdowns that occur daily on the packaging lines.

Why-Why Analysis

• WHY-1: Mechanics are still having to perform basic, routine preventative maintenance & repairs;
• WHY-2: Operators do not have the Skills & Knowledge to assist;
• WHY-3: NO FORMAL TRAINING PROGRAM EXISTS.

Developing training program

Define Skills & Knowledge

Each Module Developed with clear objectives:

1. Understanding of Normal vs. Abnormal Conditions;
2. Safe and proper use of or conditions for application;
3. Proper Component Identification;
4. Demonstrated Abilities and Skill Assessments.

Please use links below to get access to all 5 modules

• 1.0 Lubrication
• 2.0 Hand Tools/Fasteners
• 3.0 Electrical/Sensors
• 4.0 Pneumatics
• 5.0 Drive Systems

Create training schedule

Train

Benefits Old vs. New Training

Training evaluation

Group composite scores from Pre-evaluation compared to Post-evaluation scores to evaluate effectiveness. Individual Associates must have a minimum passing score of 80% to move to the next module.

Knowledge and Skill Assessment Results. Module Session Average Scores

                                               Pre   / Post

1.0 Lubrication:                    61% / 94%  (100% passed)

2.0 Hand Tools/Fasteners: 75% / 94%  (100% passed)

3.0 Electrical/Sensors:        52% / 92%   (100% passed)       

4.0 Pneumatics:                   60% / 96%  (87% passed)

5.0 Drive Systems:              50% /  92%  (100% passed)

Post-Assessment Knowledge Evaluation

Modify training

Associate Feedback = HIGHER MORALE:

• “I wish I had this training 20 years ago!”
• “I can use this.”
• “This training makes sense.”
• “No longer failures, but Planned Activity”.

Implement, Identify & Correct Abnormalities