Autonomous
Maintenance
Visual Controls
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Visual Controls
Autonomous
Maintenance
Simple definition
Normal v/s Abnormal
Obvious at a Glance
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Visual Controls
Autonomous
Maintenance
Intent
► Make the equipment easy to understand
► Reduce troubleshooting time
► Eliminate person-to-person performance variation due to skill gaps
► Improve centerline management
► Reduce operational variability
► Reduce Loss due to Changeovers
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Visual Controls
Roles and Responsibilities Autonomous
Maintenance
► Planned Maintenance and Technical Resources –
create and update site standards for visual controls
► AM Team/Operating teams/System Owners and
Area Owners – apply visual controls consistent with
site standards
AM teams make the decision about when and where to apply visual
controls to eliminate losses
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Visual Controls
How to ensure effective use of visual controls Autonomous
Maintenance
► All Visual controls must be consistent with site standards
(no deviations should be permitted)
► Visual controls must be precise and clear with Sharp lines
and good edges
► Discourage poor quality Visual controls made with markers
that have poor quality lines
► Ensure Rigorous discipline in following Visual controls
when implemented. It is not okay to have a visual control out of
spec and do nothing about it
► If a visual control is no longer relevant – have the discipline
to take it out. Have only the necessary critical Visual controls
which will be rigorously adhered to
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Visual Controls
Example Autonomous
Maintenance
Ensure consistent standards are
used to determine “how” gauges are
marked across the site
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Autonomous
Maintenance
Gauge placement not
optimized Poor access
Poor orientation
Think about the
Operator doing the
shiftly centerline checks!
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Autonomous
Maintenance
Preferred execution
Gauges grouped
Eye level
Still needs a visual control
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Visual Controls
Example Autonomous
Maintenance
These Visual Controls help on-board new equipment owners faster, reduce variation of
performance due to lack of operator experience
and help during troubleshooting
Identify all Alarm indicators, Push
buttons, Gauges and other
equipment components
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Page 9 licensed information therein may not be used or disclosed in whole or in part for any purpose other than as authorized by P&G.
Visual Controls
Example Autonomous
Maintenance
Direction mark for winding
roll in the right direction
Component
identification marks
Visual controls reduce chances of operational errors and help make
the equipment easy to understand
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Page 10 licensed information therein may not be used or disclosed in whole or in part for any purpose other than as authorized by P&G.
Visual Controls
Example Autonomous
Maintenance
Rulers as backing strips help align Easy to read pointer against scale
and position to the right points after
changeover
Helps prevent ramp-up and set-up
adjustment losses after
changeover by enabling operators
to adjust to the right place the first
time
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Page 11 licensed information therein may not be used or disclosed in whole or in part for any purpose other than as authorized by P&G.
Visual Controls
Example of defective control Autonomous
Maintenance
Scale position not repeatable.
Pointer tough to read against scale
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Page 12 licensed information therein may not be used or disclosed in whole or in part for any purpose other than as authorized by P&G.
Visual Controls
Example of defective control Autonomous
Maintenance
Scale position not repeatable.
Pointer tough to read against scale.
Same picture, different angle.
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Page 13 licensed information therein may not be used or disclosed in whole or in part for any purpose other than as authorized by P&G.
Visual Controls
Examples from BAT Autonomous
Maintenance
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Page 14 licensed information therein may not be used or disclosed in whole or in part for any purpose other than as authorized by P&G.
Visual Controls
Examples from BAT Autonomous
Maintenance
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Page 15 licensed information therein may not be used or disclosed in whole or in part for any purpose other than as authorized by P&G.
Visual Controls
Floor Exercise Autonomous
Maintenance
Participants to go on to the shopfloor and identify one potential Visual
Control application point each.
Remember that the Visual Control should preferably relate to a known
loss/stop on the machine.
All participants to report back at feedback session.
Time: 30 Minutes
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