Card: The Seven Steps of Autonomous Maintenance

Step Major activities Aims from equipment perspective Aims from human
Managers’ supervision and support
  1. Initial clea­ning
  • Thoroughly cle­an e­quip­ment and its sur­roundings
  • Remove all un­ne­ces­sa­ry mate­rials
  • Write upcoming issu­es onto four lists
  • Expose hidden de­fects by remo­ving con­tami­nants
  • Restore de­fecti­ve are­as in equ­ipment
  • Identify sou­rces of con­tamination
  • Become familiar with group acti­vity by way of easy tasks such as clea­ning
  • Group leaders learn lea­dership
  • Look at and touch every corner of equ­ipment to en­hance its care and to pro­mote curiosity and questi­ons
  • Learn “Cleaning is in­spec­ti­on”
  • Lead by staying one step ahead, compre­hen­ding TPM through prac­tice, and demonstrating with exam­ples of ma­na­gers’ models
  • Teach defects of equi­p­ment
  • Teach importance of clea­ning, lubrica­tion and ti­ghte­ning
  • Teach “Cleaning is in­spec­ti­on”
  1. Countermeasu­res to sources of con­tami­na­tion
  • Remedy sources of contaminati­on
  • Prevent conta­mi­nants from irregu­lar and unde­sira­ble dispersion
  • Improve diffi­cult clea­ning areas to reduce cleaning times
  • Prevent con­tami­nants from gene­ra­ting and ad­hering to equip­ment in order to en­hance relia­bility
  • Definitely main­tain equ­ipment clean­liness so as to im­prove main­tai­nabi­lity
  • Learn motion and working mechanism of machinery
  • Learn methods to improve equipment focused on sources of contamination
  • Encourage interest and desire to improve equipment
  • Feel pleasure and satisfaction with successful achievement of improvement
  • Teach motion and wor­king mechanism of ma­chinery
  • Teach where-where and why-why analy­ses to ex­ami­ne pro­blem
  • Assist in implemen­ting ideas for im­provement
  • Promptly respond to work orders
  1. Cleaning and lubri­ca­ti­on stand­ards
  • Conduct educa­tion for lubri­cating
  • Develop overall lubri­ca­ti­on in­spection
  • Establish lu­brica­tion con­trol sy­stem
  • Set cleaning and lubri­ca­tion stand­ards
  • Correct dif­fi­cult lubri­ca­ting areas
  • Apply visual controls
  • Definitely main­tain ba­sic equi­pment conditi­ons (cleaning, lu­brica­ting, tigh­tening) to esta­blish deteriora­ti­on prevention system
  • Set rules by on­eself and follow them
  • Know importance of fol­lowing rules and autono­mous supervi­sion
  • Encourage aware­ness of one’s own roles and team­work
  • Prepare lubrication con­trol rules
  • Provide education and practi­ce in terms of lubri­cati­on
  • Teach how to prepare clea­ning and lubrica­ting stand­ards
  • Assist actual pre­para­tion of stand­ards
  1. Overall inspec­tion
  • By each inspec­tion cate­gory:
  • Conduct educa­ti­on and prac­tice
  • Develop overall in­specti­on
  • Remedy diffi­cult inspection areas in equipment to reduce required time
  • Set tentative in­spec­ting sta­ndards
  • Detect and reme­dy minu­te de­fects
  • Thoroughly apply visual controls
  • Improve dif­fi­cult in­spection are­as
  • Maintain es­ta­blished equip­ment conditions by means of rou­tine inspec­tion to im­prove reli­a­bility fur­ther
  • Learn structure, function and in­spec­tion methods of equ­ipment to master in­spection skill
  • Master easy ser­vi­cing procedures
  • Group leaders learn lea­dership through con­duc­ting roll-out edu­cati­on
  • Learn recording, sum­mari­zation and analysis of in­spec­tion data
  • Prepare overall in­spection schedu­le, check sheets, ma­nuals, and other tea­ching materials
  • Promptly respond to work orders
  • Provide training for easy ser­vicing
  • Teach how to impro­ve diffi­cult in­spection areas by applying vi­sual con­trols tho­roughly
  • Teach inspection data h­and­ling
  1. Autonomous Mai­nte­nance stand­ards
  • Set autonomous ma­inte­nan­ce s­tand­ards and sch­edu­le to fina­li­ze acti­vities focused on e­quip­ment
  • Faithfully con­duct routi­ne maintenan­ce in ac­cordance with standards
  • Move forward ai­ming at Zero Brea­kdowns
  • Assess suc­ces­sful re­me­dies achieved in ot­her pro­cesses, and apply them to similar equi­pment
  • Totally re­view visual con­trols
  • Preserve equ­ip­ment in highly relia­ble con­di­tion along with ope­rability and maintai­nability
  • Realize an or­derly shop­floor
  • Understand equip­ment as a total system
  • Develop ability to detect signs of ab­normalities to pre­vent break­downs
  • Train knowledgea­ble ope­rators
  • Establish autono­mous supervision system con­ducted by PM group
  • Allocate inspection work
  • be­tween auto­no­mous and full-time maintenan­ce
  • Teach basic mainte­nan­ce skill and easy ma­chine dia­gnosis
  • Teach examples of bre­ak­down prevention
  • Teach particular func­tion of each piece of equip­ment to under­stand equi­pment as a system
  1. Organisation
  • Prevent outflow of de­fective products to dow­nstream pro­ces­ses
  • Prevent manu­factu­ring of defective pro­ducts
  • Attain process quality assu­rance and move forward aiming at Zero Defects
  • Assess pro­cess quali­ty
  • Attain a relia­ble pro­cess to pre­vent out­flow of quality de­fects
  • Assess quali­ty conditi­ons
  • Attain a hig­hly reliable process to prevent ma­nu­facturing of quality de­fects
  • Train knowledgea­ble ope­rators on equip­ment and quality aiming at new type of engi­neering sta­tus
  • Attain autonomous su­pervi­sion wit­hin each operator
  • Teach quality spe­cifi­cations, quali­ty cau­ses and qua­lity re­sults along with their relati­onship
  • Teach the five cri­te­ria for ease of obser­vation
  • Teach the five cri­te­ria for quality assu­rance
  • Address matters of quali­ty with coop­era­tion by all re­lated departments
  1. Autonomous mainte­nance
  • Maintain, im­prove and pass on cur­rent TPM levels
  • Calculate the Overall Equipment Effective­ness (O.E.E.)
  • Analasis of the failure of the equipment
  • Predict ab­norma­lities to pre­vent break­downs and quality de­fects prior to occurrence
  • Attain Zero Ac­cidents, Zero Break­downs
  • Move forward aiming at higher level of produc­tion technology
  • The O.E.E. shows the week spots of the equip­ment
  • Firmly establish self-su­per­vision to be able to deve­lop factory’s strate­gy by SGA groups them­selves without ma­na­gers’ detai­led in­struc­tion
  • Detect and resol­ve ari­sing pro­blems by SGA gro­ups themselves by way of short re­medial program
  • Assisting with the calcula­tion of the O.E.E.
  • Assist activities to maintain, impro­ve and hand down cur­rent TPM status
  • Encourage further im­prove­ment of tec­hnical kno­wled­ge and skills
  • Move froward toward the second genera­tion of TPM
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