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Maintenance: autonomous maintenance
Kaizen Book n.8.1
Losses due to scarce cleaning
Example
After
Befor
e
Forced deterioration
In presence of dirt and scatterings, it is difficult to check and detect loosenings, cracks,
clearance, lack of oil, with subsequent continuous forced deterioration
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Losses due to scarce cleaning
Breakdown
The infiltration of foreign bodies in rotating parts, in sliding parts, in pneumatic and
hydraulic systems, in electric and control systems, in sensors, etc. generates
malfunctionings and breakdowns due to use, obstruction, resistance and feeding of
inadequate power
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Key points: initial cleaning

Initial cleaning is the first activity of Autonomous Management
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Safety must be the top priority
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Operators must become aware of the fact that keeping the
machine clean is one of their jobs
All the dirt that has accumulated over the years must be
completely removed
Lids and safety panels must be opened and internal parts of the
machine must be cleaned, too
The auxiliary parts of the machine must also be cleaned
All the unnecessary objects close to the machine must be
removed.
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Initial cleaning - Familiarize with the machine:
HUH?
I didn't know there
was a lubricator
there!!
This first level of awareness is the opportunity to start a training process
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Initial Cleaning - Discover anomalies
No cover!
Too much
grease!
I start cleaning myself
with a cloth
The oil level is
not visible!
In this way I can
discover all the
anomalies!
I must inspect the machine,
even inside
Excessive oil
leak
Too much
dirt and
lack of
grease
Is pressure
OK?
Cleaning means inspecting
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Example
Hidden
Evident
What is happening
under all this dirt ?
During cleaning activities, a crack has been identified in the base of Banbury mixer
number 1. If the crack had been ignored, the base would have broken and it would
have taken two weeks to replace it.
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Initial Cleaning - Identify contamination sources
All this dirt prevented
me to see the leak!
And discover the source of
dust and dirt
Start to understand the importance of keeping
everything clean
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Continuous inspection and tagging
Put a tag where there is something wrong
Tagging:
It highlights improvement opportunities of the machine
It is an opportunity for operators' training
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Continuous inspection and tagging
Example of anomalies
Machine
Project no.
Type of anomaly
Possible intervention
Found
Done
Lack of lids, safety panes
Difficult inspection of internal areas
Lack of valves and pressure gauges
Indication of the
correct pressure
Hard-to-clean places
Fluid leaks
(water - air - oil - steam)
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Continuous inspection and tagging
Example of anomalies- 2
Type of anomaly
Other anomalies
Possible intervention
What's
it for?
The
door
does
not shut
Found
Done
Are there
tags?
A bolt is missing!
Lack of stickers indicating motor
temperature
Lack of transparent inspection doors
Thermoresistant
stickers
Direction of belt
and chain
rotation
Acrylic material window.
Belt model and series
number
Lack of different blocking reference
systems
Misaligned chains, joints
Lack of identification of open / closed
valves
Difficulty in lubricating and in carrying
out controls
Does the quantity of
oil belong to the
appropriate range?
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Continuous inspection and tagging
The use of tags
TPM
Name
Date
Plant
Area
Shift
D
Anomalies observed
Neron
e
7 - 6 - 1994
111
removable
5
lid
A
B
Fill in the tag and hang it where the
anomaly has been detected.
If the anomaly appears on a mobile part,
the tag should be placed as close as
possible.
C
X
Oil leak
I
Low
Water leak pressure
Ait leak
J
Noise
Grease leak K
Steam leak
Defective parts
Vibrations
L
High
Abnormal function
M
Difficult
High
to clean
N
Obstacles to clean
Use the back to write
P
Missing
suggestions
Other
anomalies
screws/bolts
Q
Sheath
withdrawn
A
B
X
C
D
E
F
G
temperature
H
pressure
Tag no.
199
Action taken
Date ............. who .................................. sign
...............
Tagging is a continuous action!
Always keep the
original!
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SOGEFI KAIZEN WAY
Maintenance: autonomous maintenance
Kaizen Book n.8.1
Continuous Tagging
Tagging rules
1 - Detect machine anomalies (of any
type, even those that seem
insignificant).
3 - Attach the tag baside the detect or where the
breakdown was found. If the anomaly is found
on a moving part of the machine, attach it as
close as possible.
4 - Record the data on the tag on the register book.
Make sure the number, description of the
anomaly, and its position on the machine are the
same on the tag and in the register book.
2 - Fill in the tag. Clearly insert the data that is
required (see example).
Tagging is a continuous operation: every time you find an anomaly on
the machine, you have to tag it!
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SOGEFI KAIZEN WAY