rsa reliability and maintenance consultancy firm …rsareliability.com/am7 brochure for in-house (3...

Autonomous Maintenance 7 StepsTo Operators Journey to Empowerment

Training Package Includes:

• 1 Complete Handouts on the course

• AM/PM and Lunch included

• Selected Articles on AM

• Exercises and Handouts on AM

• CD Copy of AM Training per Delegate

• Certificate of completion

• Roadmap of Activities per Step

Who Should Attend:

• Operators and Maintenance Managers

• Production Managers and Supervisors

• Preventive Maintenance Group

• Predictive Maintenance Groups

• Reliability Engineers and Managers

• Maintenance Planners

• People in charge of Lubrication

• Operations and Production Supervisors

• Management and Decision Makers

• TPM Office and Facilitators

• Continuous Improvement Groups

• Equipment Engineers

About the Resource SpeakerRolly, is a seasoned international reliability and mainte-nance consultant with 29 years of experience in the field. He had been invited in different countries and have conducted reliability and maintenance trainings in India, Malaysia, Indonesia, China, Thailand, UAE, Botswana, South Africa, Brunei, Nigeria and Bangladesh. His portfolio of maintenance trainings include Maintenance Management courses such as Total Productive Main-tenance, Lubrication and Tribology, Condition-Based Maintenance, Reliability-Centered Maintenance (RCM), Root Cause Failure Analysis, Planned Maintenance, World Class Maintenance Management, The 12 Disciplines, Oil Contamination Control, Maintenance Indices and KPI’s, Maintenance Management System and much more. Rolly previously worked with Amkor Technology Philippines as a TPM Senior Engineer, an industry engaged in the manufacture of Integrated Circuit products and spearheaded their Planned Maintenance organization compose of maintenance managers and engineers. He was responsible for the dramatic reduction of unplanned breakdowns in their TPM Journey as well as RCM implementation on their Facilities Air Handling Units and as well as their sub-station equipment. Rolly is currently working as an independent reliability and maintenance consultant.He had released 2 books on maintenance World Class Maintenance and Maintenance – Roadmap to Reliability.

Autonomous Maintenance ClassBotswana Ash, Botswana, Africa, July 2013

Autonomous Maintenance ClassPIPAVAV, Gujarat, India, January 2012

Reliability and Maintenance Consultancy Firm PresentsRSA

Serving Maintenance Mankind

Proposed contents and module for in-house training

ENROLL NOW Email:[email protected]: http://www.rsareliability.com

Contact Number: +63920-482-8225

AM Course ObjectiveBrief Course Overview• This course shows the importance and bene-

fit of introducing an Autonomous Maintenance

program and what it will achieve if correctly

applied in the workplace.

• Autonomous Maintenance is the activities in

which each worker performs daily cleaning,

lubrication, inspection and parts replacement

in order to establish Basic Equipment

Condition

• This course tells us the importance that

Autonomous Maintenance is not just the

transfer of task to operators but teaching

operator that their responsibility does not

end from just operating the machine itself

Autonomous Maintenance is changing the

mindset of operators from the traditional

I fix you operated to, we operators take care

of our equipment together. Maintenance

can only escape the viscous cycle of being

reactive if operators partner with them in

improving the reliability of their equipment.

• To provide an overview and awareness on the

benefits that can be derived in implementing

Autonomous Maintenance

• Understand the detailed step by step approach

in implementing Autonomous Maintenance pillar

• To develop reliable manufacturing assets

through involvement of all shop floor people in

a structured and detailed step

• To develop an in house Autonomous Mainte-

nance people that will drive the implementation

of the pillar in their plant

• Understand the role of maintenance in develo-

ping their Autonomous Maintenance Pillar

• To enable operators to understand that mainte-

is a shared responsibility for both the operators

and maintenance function

Long term benefits of Autonomous Maintenance to plant equipment especially with an ageing plant like Pagbilao as well as to the plant operators. Autonomous Maintenance can improve or will help improve operator skills in equipment monitoring and maintenance. From Eric Salvacion, Shift Manager, Team Energy Corporation, Pagbilao

There were no dull moments during the 3 days training on Autonomous Maintenance. Technical learning’s were more strengthened and clearly understood through easy to relate stories, videos and clips. I wish that a time will come when people in the workplace will all think and do like this.From Jun Sainz, Coal Superintendent, Team Energy Corporation, Pagbilao



Feedback





Autonomous Maintenance Day 1

0830 - 0830 - Take AM Pre IQ Quiz

0830 - 1000 - Module 1 : TPM Overview

- Getting the edge with TPM

- TPM Basic Concept & TPM Pillars

- Operators and Maintenance –

Industry partners for life

- Importance of Autonomous

Maintenance in improving the

reliability of equipment

1000 - 1015 - Morning Break / Meals

1015 - 1100 - Continue Module 1

1100 - 1200 - Module 2 : AM Overview

- Typical operator’s culture

- Concept of Autonomous Maintenance

- Establishing Basic Equip Condition

- Skills operators need

1200 - 1300 - Lunch

1300 - 1500 - Module 3 : Step 0 : Basic

Training & Preparation

- Understanding Basic Machine Function

- Maintenance guidance for Autonomous

Maintenance activities

1500 - 1515 - Afternoon Break / Meal

1515 - 1630 - Module 4 : Step 1 : Perform

Initial Cleaning

- Importance of Cleaning the machine

- Understanding abnormalities

- Types of Contamination

- Step 1 Flow of Activities

1630 - 1700 - Exercise on types of Abnormality



- Take quiz on Types of Contamination

1100 - 1200 - Module 7 : Basics of Lubrication

and Contamination Control

- Understand how oil is contaminated

- Contamination Control Awareness

1200 - 1300 - Lunch


1400 - 1500 - Module 8 - Step 3 : Establish

Equipment Standards

- Types of standards



1515 - 1700 - Module 9 - Step 4 : Develop

General Equipment Inspection

Procedures

1700 - End of Seminar on AM Day 2

Autonomous Maintenance DAY 2

0830 - 9000 - Module 5 : Visual Control

In The Workplace

- Samples of Visual Control

Autonomous Maintenance Day 3

0830 - 1000 - Module 10 : Step 5 : Conduct

General Equipment Inspection

Autonomously

- Finalize inspection process

- Step 5 Roadmap of Activities


1015 - 1200 - Module 11 : Step 6: Manage

Systematic Autonomous

Maintenance in their Workplace- Developing 5s in the workplace

- Step 6 Roadmap of Activities

1200 - 1300 - Lunch

1300 - 1400 - Module 12 - Step 7 : Achieve

Empowered Autonomous

Maintenance in the Workforce- Achieving an empowered workforce



1515 - 1600 - Workshop and Exercise

1600 - 1700 - Take final IQ Quiz on AM

- Closing Remarks

0900 - 1000 - Module 6 : Step 2 : Address

Sources of Contamination

- Improving Hard to access areas

- Different types of Contamination








• Full of live stories that reveal whats goin on in reality off work and on work. Example of Rollings Stones musical

group that remained together for a long time because of respect for one another

and working as a team. Chiyapo Kajala, Botswana Ash

• A very good and informative training for both operations and engineering maintenance. Onkemotse Seelo, Botswana

Ash

• Gives every worker strenght to work hard and reduce the breakdowns in the plant and everyone to be self-driven in

his work. From Moitsisi Moutlwatsi, Botswana Ash

• Everthing about the course is very good and educative and can really change aman to the better.

From Elvis Kgomosetso , Botswana Ash

• The course itself and its materials were good in such a way that we learnt that we have been doing things the wrong

way. Hopefully as from nowwe will improve and our company will bevery good in both improvements and human

improvements. From Godfrey Gondo, Botswna Ash

• Explanation of elaboration via videos helped a lot . Fact that plant health is a responsibility of both maintenance

(engineering) and production (operation) Tholego Saboy

• Instill the sense of ownership in employees. Empowers to make decisions and most importantly to enjoy their work.

Diversify of thinking and ways in which things were done. Cultural aspect of companies wa they get tied to old

systems which at times don’t serve any purpose. Maenge PG Maenge, Botswana Ash

• I was impressed of all trainings, it was really good. The instructor has a good communication skills. From Meleco

Mochi, Botswan Ash

• Autonmous Maintenance is a good course to Botash and need 100% commitment from both operations and

engineering. From Gabedi Abofi



Autonomous Maintenance Batch 1July 12 to 14, 2013

Botswana Ash, Botswana, Africa

Autonomous Maintenance Batch 2July 16 to 18, 2013

Botswana Ash, Botswana, Africa


Testimonies and Feedback:







Testimonies and Feedback:• Learn additional knowledge about Autonomous Maintenance. On this training, we learned and develop our knowledge about Planned and Autonomous Maintenance. We really appreciate this kind of training. Enjoy and feeling thankful. From VilmaSisante, Team Leader Excelitas Technologies

• Training was execute very well. Information were all relayed effectively in a realistically and interesting manner. Every topic was taught with a sharing of experience by the trainer which makes it to be easy to understand. It has been a long time since I met a trainer this effective. Continue with your style and training approach. From Portia Chandiramani, Process Engineer, Excelitas Technologies

• Great visual aids. Fun entertaining ice breakers. Educational ice breakers. Educational and interactive workshops. Great delivery technique of the facilitator. Change in mindset/paradigm is very timely and necessary. Chocolates. :-) From Lady Jett Padua, Process Engineer, Excelitas Technologies

• Good points about this training is the outline of the course, detailed steps. Discussed expected difficulties to be encountered along the way. Applicability of each step to current culture of the company. Technical yet fun. Rolling Stones music video. Everything about it was good. From Kevin John Mariano, QAE, Excelitas Technologies

• Trainer is enthusiastic to train and share his knowledge and experiences regarding the course. The content of this training clearly plotted out the step by step procedure on how to implement Autonomous Maintenance. The workshop was also interactive and encourage the participation of the attendees. Bonus treats further motivated the team members. :-) From Angie Sapulmo, Process Engineer, Excelitas Technologies

• Autonomous Maintenance is a very good tool to empower operators. AM concept includes developing the skills and mindset of operators as well as Planned Maintenance who will be doing the training. This will improve productivity, quality and not to mention safety. Congratulations Sir Rolly Angeles. From Philip dela cruz, Facilities, Excelitas Technologies

• Fun, entertaining, great facilitator. The content of the training plotted out the step by step. Easy to understand each detail and very educational. Rolling Stones. :-) From Lani Raymundo, Operator, Excelitas Technologies

• Good points about this training is empowering the operators with using the 7 steps of Autonomous Maintenance. Being a self directed employee that gives confidence to an employee to love his/her. In order to be a success, operator and maintenance must have good communication. From Lory Cuasay, Operator, Excelitas Technologies

• Knowledge of the speaker on the training. Visual examples and simplicity of terms used so that other non technical participants understands the discussion. The training is full of good ideas and information that refreshes our knowledge of the topics. Group activities are good that triggered our minds to think and to know what we learned. From Rommel Ignacio, Equipment

Engineer, Excelitas Technologies

• Maintenance and operators can now help each other to reduce the downtime in our machine. We are now ready to teach operators about our knowledge in machine trouble shooting. Maintenance and operators will help each other in taking good care of their machines. Old culture will be step aside and new and good culture will arise so we can reduce our downtime. From Christopher Macabutas, Lead Technician, Excelitas Technologies







Testimonies and Feedback:• The training is good for the operator because it reduces a lot of downtime and it enables the operator to do his/her job

well done and sees the problem before it occurs. Also the operators and maintenance teams up and they join hands

together to have a one solid team and provide good results in the future. From Mooketsi Mpebe, Operations, Botash

• This bought to light the role and importance of lubricants in equipment. The use of oil analysis to determine machine

failure. Correct and better filtration techniques. Importance of having our own oil analysis facility and its benefits.

From Knomotso Mopipi

• It improved my understanding and be able to work together with maintenance personnel to prevent continuous

breakdown of equipment. From Thato Nchenje

• I learned a lot of things that I did not know about since this was my first training to attend. This will bring change to our

company if we people, the employees and the management change and be a good company with less breakdowns.

This will show our management team the good and bad aspects that need to be fixed and change even though this is

a big decision to do but I believe that Autonomous Maintenance can only work if we forget about how much years and

money it will take vs cost. But if we want to change Botash will be a better company in the world. From Otang

Sibawela

• Will improve the downtime of the equipment after the operator has been trained and empowered to look after the

equipment. We need to start as soon as possible. From Samir Bandyo Padhyar, Power Plant, India

• This training, I like it because it has improve me on the plant. How to save the equipment life span and in cleaning,

checking, lubricating, tightening, operation contamination sources like gases and liquids etc., so I need another step

on this course so that I can improve again the plant availability as well. From Rebagoho Gaatshameke

• Operation will share the responsibility on the machine. The relationship between operation will improve, hence less

downtime and breakdowns. Less cost since the operator will attend the problem early. Create new departments

which will monitor the plat machinery. From Brown Gabosebiwe

• Good relationship between workers. Empowers the operators on how to take good care of the equipment in our

plant. From Samson L. Plant Operator, Botash Ash

• Autonomous Maintenance can be good in our equipment or our plant in terms of time delaying of fitters on

maintenance when they have worked off. It can also give as a knowledge about how important is our equipment and

how to protect it in a safer way in terms of repairing the equipment. To develop skill in operation, build team work in

both maintenance and operation strongly to develop operators to be independent on his self to do their jobs. From

Olladi M. Salt Plant , Plant Attendant, Botash Ash

• It improves the operator to understand fully the equipment that they are running and in terms of design , structure and

operation. It also reinforces operation, maintenance relation in a positive way. Operation and maintenance should be

in a harmonious relation in regards to the plant running and maintenance. From Gaone Bogopa, Plant Operator,

Botash Ash






Autonomous MaintenanceNovember 19 to 20, 2015

Transition Optical, Philippines


Autonomous Maintenance Workshop:

Autonomous MaintenanceApril 6 to 8, 2016

Team Energy Pagbilao, Philippines

• This is a very empowering course not only for operators but also some maintenance people should undertake it

because it covers all faculties of engineering, mechanics, electrical, pneumatics and tribology so this type of a course

have a provision for multi-skilled workforce. From Oeoi Seisa, Plant Operation, Botash Ash

• The Facilitator is very knowledgeable with good experience. Most of his points were exactly what we have in the plant

as our short comings. Example oil storage if I were to give example as well as mixing of lubricants in the equipment.

Dithutego Zambo, Intern Engineer, Bostash Ash




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