Autonomous maintenance preparation system design with axioms

Abstract

PurposeThe purpose of this paper is to support total productive maintenance implementers by providing a roadmap for autonomous maintenance (AM) preparation phase.Design/methodology/approachThe authors use the axiomatic design (AD) methodology with lean philosophy as a paradigm.FindingsThis is an exploratory research to find the most important factors in AM preparation phase. A decoupled AD design ensures an effective usage of training within industry (TWI) and the introduction of standardized work (SW). TWI provides value in importance it assigns to leaders, with its “train the trainers” approach and in preparing a training program. Besides being an effective training method, TWI job instruction (TWI JI) provides needed information infrastructure to front load operators SW and equipment trainings.Research limitations/implicationsAlthough AD, TWI and lean artifacts are generally field proven, the research is limited due to the lack of an industrial application.Practical implicationsIn many real-life projects, companies do not know where to start and how to proceed, which leads to costly iterations. The proposed roadmap minimizes iterations and increases the chance of project success.Originality/valueThe authors apply AD for the first time to AM preparation phase despite it is used in the analysis of lean manufacturing. AD permits to structure holistically the most relevant lean manufacturing solutions to obtain a risk free roadmap. TWI has emerged as a training infrastructure; TWI JI-based operator SW training and the adaptation of JI structure to equipment training are original additions.

Improving the performance of a conveyor belt through lean philosophy and Industry 4.0

“…The introduction of either AM or TPM Through this pillar, operators empowered by the correct education and training, learn to perform important daily tasks that maintenance technicians rarely have time to perform. These tasks include cleaning the machines and equipment they operate, lubrication, small adjustments, as well as routine inspections, to reduce deterioration and prevent failures in machines and equipment in the manufacturing system (Bashar et al, 2022;Singh and Gurtu, 2021;Muftuoglu et al, 2022).…”

“…Thus, the operator becomes a key element, as he will be responsible for carrying out small maintenance activities. The operator having this attitude will feel like another important element, which will help in his development and taste for the job, as well as helping to create more time for the maintenance team, leaving more time for more time-consuming and complex tasks, making improvements to machines contributing to increased productivity (Bashar et al, 2022;Muftuoglu et al, 2022).…”

“…By ensuring that all machines and equipment in the production system are properly maintained, including regular cleaning, timely repairs and well-trained and qualified operators, it leads to increased productivity and improved performance (Singh and Gurtu, 2021;Muftuoglu et al, 2022).…”

“…These tasks include cleaning the machines and equipment they operate, lubrication, small adjustments, as well as routine inspections, to reduce deterioration and prevent failures in machines and equipment in the manufacturing system (Bashar et al. , 2022; Singh and Gurtu, 2021; Muftuoglu et al. , 2022).…”

Axiomatic design for lean autonomous maintenance system: an application from textile industry

“…The decision framework of this study is based on two technical decisions, namely, identifying critical components for maintenance and determining the right AM activities. Muftuoglu et al (2022) focused only on the preparation step of AM via AD. However, the study neglected the design of core steps for AM such as initial cleaning, overall inspection, AM standards and autonomous supervision.…”