Take countermeasures for contamination sources

Set provisional standards for cleaning, checking and lubrication

Conduct general inspection training

Conduct autonomous inspection

Standardize and sustain

Autonomous management

0

Conduct initial cleaning and inspection

Education and training

The 7 Steps of Autonomous Maintenance

1

2

3

4

5

6

7

Start up phase

Development phase

Maturity phase

Nakajima

TPM Team

Fuguai-Tagging, photo, F-Tag register

PlanningWith Risk Assessment

AuditNext step

Deploy to other area

Action

Implementation, de-tagging, photo, documentation

Step 1, Conduct Initial Cleaning and Inspection

Step 1, Conduct Initial Cleaning and Inspection

Step 1, Conduct Initial Cleaning and Inspection

Initially, cleaning takes long time

1. Difficult to access area

2. Sources of contamination

Difficult to accessNo place for standingInspection is blocked by wiring and piping

Water, Oil, Debris, Powder, Dust, etcDebris collectionIncrease number of cleaning

TPM Team

Action

Step 2, Countermeasures for contamination sources

Model line

Deploy to all equipments

Inspection window

Difficult for lubricationCleaning more than 5 minutes

Difficult for inspectonIneffective tightening

Lubrication causes dirt

New group

Step 3, Provisional Standards, Part 1

Step 3 Provisional Standards, Part 2

Lubrication Management

Number of Lubrications, Lubricants visual Management

Use as standard time for manpower allocation

Use as standard time for manpower allocation

Learning from Step 1,2

Discussion with Maintenance and Engineering

Draft cleaning and inspection (Lubrication) Provisional Standards

Develop new lubrication test point

Conclude cleaning and inspection provisional standards

Review improvement results

Step 4. Conduct general inspection training

Step 4. Conduct general inspection training

Step 5. Conduct Autonomous Maintenance

Step 5. Conduct Autonomous Maintenance

Step 6. Standardization and Sustain

Step 6. Standardization and Sustain

Step 7. Autonomous Maintenance Management

TPM process Ref. Borris

Training Matrix

Ref. Borris