MACHINECLASSIFICATION

AUTONOMOUS MAINTENANCE
Standard Title Machine classification (reactive phase)

Revision # 1

Revision Date January 26, 2016

Prepared by Felipe Barragan / Dicky Haryanto / AM Pillar Circle

Approved by Enzo Benelli

Revision History
Revision Date Revision # Prepared By Reason for Update

F. Barragan / D.
Apr 27, 2016 1 New
Haryanto

TRAINING OBJECTIVES
At the end of the training you will be able to:Pillar(s)

Explain how to classify your machines into AA,A,B, C classes in order

to implement the AM pillar activities following a defined machine
prioritization.

Explain how to define the model machines for AM

Start using the machine classification reactive in your factories to

define the AM model machines and expansion plans
MACHINE CLASSIFICATION REACTIVE PHASE

The machine classification standard is implemented to classify the machines in the

factory in selecting the model machine and prioritizing the expansion.
MACHINE CLASSIFICATION
REACTIVE
 What is it?
When to use it?
Where to use it?
Who uses it?
Which losses does it
attack?
How to use it?
Is a method to prioritize the
machines to implement AM
step by step activities in a
way that delivers the highest
cost benefit for the factory. In
the reactive phase the machine classification is done based on Cost Deployment.
Machine classification reactive is used from the preparation activities to launch WCM until the
factory has implemented AM steps 1-3 in their AA-A-B machines achieving zero breakdowns. It is
used to define the AM model machines and the expansion plans.
A machine classification proactive exists but will be covered in a different standard
All the machines covered by the CD cycle up to covering the full factory
AM pillar teams, in conjunction with PM and CD, to define their model machines and expansion
plans. Factory leadership team
Time loss Energy loss N/A
Method to define the prioritization of machines to
Material loss Manpower loss implement AM pillar activities
Reactive phase:
- Start measuring breakdowns and their split by their 6 root causes
- Measure the Cleaning, Inspection, Lubrication, Re-tightening (CILR) time and find any resultant
losses ( To be used in AM machine classification)
- Run the first CD cycle
- Identify the breakdown loss cost due to lack of basic conditions + the time loss cost related
to
CILR time losses in order to define the AA-A-B-C classification for AM
- Assign AA-A-B-C class to each machine following the 50-70-90-100% rule based on CD.
AM MACHINE CLASSIFICATION
REACTIVE
Steps to follow to classify the machine at the beginning of the WCM implementation
(reactive phase) based on Cost Deployment (CD)

1. Collect breakdown data per machine and their 6 root causes for the areas where the
first CD cycle will be completed. Provide this data to the CD pillar to complete their first
CD cycle

2. Collect maintenance time loss data related to Cleaning, Inspection, Lubrication and
Re-tightening CILR activities for the areas where the first CD cycle will be applied.
Provide this data to the CD pillar to complete their first CD cycle

3. After C matrix is done, select the breakdown due to lack of basic conditions loss
cost + CILR loss cost to determine the AM machine classification and model
machine following the criteria below:
 ~50% of the AM Breakdown The AM model
AA machine
+ CILR loss costis the No. 1 AA machine!
A
Up to ~70%
B Up to ~90%
C Up to ~100%

From C matrix loss To Pareto of AM Breakdown
AM
cost Pareto + CILR loss cost by machine
CD
Strong collaboration
between CD, AM and
PM is needed to
PM properly stratify the
breakdown loss cost

CILR loss cost from

CD

AM breakdown loss
cost from CD

AA-A-B-C MACHINE
The AM CLASSIFICATION
model machine isthe No. 1 AA machine!
7
AM PILLAR EXAMPLE
MODEL MACHINE DEFINITION IF CD
IS NOT AVAILABLE
AM
PILLAR
EXAMPLE
Create Pareto # of all
breakdowns by machine.

Create Pareto of CILR cost

by machine

Define your model

machine based on
highest # of breakdowns
and
CILR time cost. This
should only be used in
absence of CD cycle
results
 CD Strong
collaboration
AM The AM model machine is the machine with the highest breakdown and CILR cost
PM

As soon as the 1st CD cycle is complete the

model machine needs to be validated based on
CD
8
Source: Katowice
 Questions
TRAINING ASSESSMENT QUESTIONS
1. Question: When do you do the machine classification reactive phase?
a. After the 3rd Cost Deployment cycle
b. When advancing into AM step 4
c. From the preparation activities to launch WCM until the full factory has achieved AM steps 1-3 in AA,
A, B machines
 d. None of the above
2. Question: What is the machine classification used for?
a. To define the AM and PM model machines
b. To define the AM model machines only
c. To define the PM model machines only
d. To define the AM and PM model machines and AM and PM expansion plans
3. Question: What is the scope used to do the machine classification into AA-A-B-C? a.
The machine with the highest cost
b. All the machines covered by the CD cycle up to covering the full factory
c. Model line
d. The area with the highest cost
4. Question: What is the criteria used to define the machines into AA-A-B-C in AM Pillar?
a. 50%-70%-90%-100% of the AM breakdown loss cost+ CILR loss cost for AM
b. 50%-70%-90%-100% of the AM breakdown loss cost
c. 50%-70%-90%-100% of the total breakdown loss cost
d. a and b
5. Question: Are the AA-A-B-C machines always the same?
a. Yes, to be able to prioritize the same machines and reduce the overall breakdown loss cost
b. Yes, only one machine classification is done using the same criteria for both pillars
c. No, each classification uses different loss cost data thus their model machines could be different d.
None of the above
USEFUL LINKS
AM step 0 training PM step 0 training
KEY LEARNINGS

The machine classification should be done considering all machines

covered by the CD cycle up to full factory

The machine classification - reactive is based on Cost Deployment

results considering the AM breakdown + CILR time loss cost for AM
and PM breakdown loss cost for PM

The machine classification - reactive phase is used from the

preparation activities to launch WCM until the factory has implemented
AM and PM steps 1-3 in their AA-A-B machines achieving zero
breakdowns

The machine classification reactive is used to define the AM and PM

model machines and the AM and PM expansion plans