Autonomous Maintenance: A Case Study on Step – 0 to 3 Implementation at Detergent Packing Machine in FMCG industry

Abstract

Businesses in the Fast-Moving Consumer Goods (FMCG) sector always work to improve the efficiency of their manufacturing processes in order to keep a competitive edge in the fast-paced and cutthroat business. With a focus on the detergent packing machine at an FMCG manufacturing plant, this case study explores the application of autonomous maintenance (AM), a key component of the Total Productive Maintenance (TPM) philosophy. Finding and removing losses from the manufacturing process, especially those involving equipment and plant, is the main goal of AM. The four main phases of the step-by-step process described in the AM technique are Step0, Step1, Step2, and Step3, each of which aims to restore the fundamental machine conditions. The AM process's cornerstone, Step 0, emphasizes the necessity of a change in the maintenance staff's perspective. In this level, operators and maintenance teams would discover the value of autonomous maintenance and be instilled with a sense of ownership and responsibility for the equipment. The emphasis switches to cleaning and inspection tasks in Step 1. The detergent packing machine is thoroughly cleaned and carefully inspected to look for any indications of wear and tear or possible problems. This stage lays the groundwork for future enhancements by attempting to create a baseline for the machine's current state. The second step is to establish performance and cleanliness standards for the machine. For regular cleaning and inspections, standardized protocols are created to provide uniformity and predictability in maintenance tasks. In order to improve operators' and maintenance personnel's abilities to recognize and handle possible problems, this stage also includes training courses for them. Step 3 focuses on maintaining the progress made in the preceding steps. It entails creating an organizational culture of proactive maintenance where the idea of continuous improvement permeates every aspect of the business. To make sure that the set standards are being followed and that any deviations are quickly corrected, audits and reviews are carried out on a regular basis. This case study demonstrates the effective use of autonomous maintenance at the detergent packing machine in the FMCG sector by carefully following these four guidelines. The outcomes include a significant reduction in costly breakdowns, improved machine reliability, and the cultivation of a culture of continuous improvement, contributing to the overall competitiveness of the company's products. The lessons learned from this case study can serve as valuable insights for other companies looking to embark on a similar journey of enhancing their manufacturing processes through Autonomous Maintenance.