Implementation of the autonomous maintenance pillar of total productive maintenance on a Newton GHN-3013 guillotine shear

Abstract

The proposed study presents the results of the development and implementation of TPM (Total Productive Maintenance) techniques in a company in the southern region of Santa Catarina. The work was initiated to improve the production flow in the cutting and bending sector of a local metallurgical company. This need was reported by some employees during a KAIZEN (continuous improvement group) event, where they stated that as demand grew, the need arose to increase productive time, thereby increasing the productivity and efficiency of the machines. For this, the first pillar of TPM, AM (Autonomous Maintenance), was used. AM aims to reduce corrective maintenance and prepare machine operators so they can understand, manage, and improve their equipment, eliminating small errors and failures that could lead to major stoppages and unnecessary maintenance. To achieve this level of operator knowledge, a four-phase system with seven steps was used to reach complete machine autonomy. The first phase consists of cleaning and restoring the machine, distributed in 3 steps; the second phase involves standard lubrication in just one step; in the third phase, a standard inspection was carried out in one step; and in the fourth and final phase, the main objective was achieved: AM, divided into two steps. At the end of all the steps, the understanding is that operators should be able to identify and even eliminate minor errors. To verify the effectiveness of this process, AM was implemented on the NEWTON GHN-3010 guillotine shear. With a positive result, it will be possible to implement this technique on all machines in the sector in the future. The goal is to reduce the amount of maintenance and improve productive performance.