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Steps Contents of Activities Remark

Key activities for initial cleaning include:  The time required to complete
1 Initial Cleaning:  Perform all activities necessary to shut down, isolate and make the equipment the above steps may exceed
or process area totally safe to operated available time for a given
 Obtain copies of equipment drawings, documentation, history and other shutdown period. It may be
relevant information. If drawing do not exists, prepare sketches of the necessary to schedule the above
equipment or scan photographs for use in documenting lube points adjustment steps over several shutdown
points and process check points. This documentation is used in successive periods to accommodate
levels of autonomous maintenance to develop stands for lubrication and operating requirements.
autonomous inspection.  Dozens of equipment
 Document initial condition of the equipment through photographs. Prepare abnormalities or improvement
forms for documenting equipment defects and tags for making items needing suggestions may result from the
further inspection. initial cleaning activities on a
 Segment portions of the machine or process area and plan how to clean the single machine. Many of the
machine with maximum efficiency and effectiveness. equipment issues will be fixed
 Obtain hand tools, rags, brushes, solvents, mops, brooms, scrapers and other or improved immediately
tools required to perform the cleaning tasks. during the initial cleaning
 Clean each machine segment in a methodical manner. (Remember that the goal activities. Others will be
is to put the machine back into as new condition as possible.) backlogged as work request to
 Remove all dirt, grime, dust, grease, oil, sludge, chips, mists, trash and excess be performed by skilled trades
materials. or external contractors.
Note any equipment abnormalities such as broken switches, bent guards,  Depending on existing
missing bolts and leaks. equipment conditions, initial
 Tag and document all equipment abnormalities. Address easily corrected cleaning activities may require
abnormalities immediately and write work request for other abnormalities a major commitment of time
found. and resources.
 Re torque all bolts including hold down, fasteners, adjustment and structural Most companies
bolts. Mark all bolts by painting a stripe across the stud head bolt and the bolt underestimate the size of
to indicate the relative positions of both when properly torque. the commitment. Once they
Any future slippage or loosening of the bolt then can be noted easily as the recognize the extent of
marks will no longer line up together. resources required they
 Repaint areas if necessary according to predetermined specifications. either cut back on the
The purpose of repainting is not just to prevent corrosion but to provide a amount of equipment to be
surface that can be examined easily for cleanliness. Color codes the included or perform only
piping, utilities, and guards for ease and observation. superficial cleaning.
 Note and mark all lubricating points.
Document the points on a lubrication chart and mark the point physically
on the machine.
Color coding can be performed by painting a small colored circle in close
proximity to the lubrication point. Some plants use plastic colored sticker
to mark the position and lubricant type instead of a paint circle.
The color of the circle designates the type of lubricants to be used.
Lubricant containers can be color coded by painting the container the
same color as the lubrication point circles.
 Photograph the clean machine or process area and compare with a before and
after photograph to verify the machines progress on initial cleaning.
 Formally turn the equipment or process area back to production for startup and
Have the small group participate in the setup and startup activities for
greater understanding of their equipment.

2 Address Sources  Contaminant identification

of Contamination  Typical contaminant type should be identified and documented. cannot always be accomplished
and Inaccessible during the initial cleaning
Areas: Typical contaminants include: activates.
Leaking process fluids,  Much time, due to the volume
Leaking lubricants, of the contaminant and the
Dust, years of buildup, the initial
Corrosion clean-up activity can identify
Process only that a contaminant exists.
Material handling scrap
Worker generated trash
Other external pollutants.

3 Establish  Cleaning Standard Small groups should be responsible for

Cleaning,  Inspecting Standard developing standards for equipment in
Inspecting and  Lubricating Standard their areas.
4 General  Operators will learn how to perform inspection of the basic mechanisms of the  On the basis of which
overview of the machine. maintenance workers will train
machine.  Knowledge transfer requires the creation of manuals, operators
(Train for general  Conduct in depth training with the operators to explain the function and  The result will be the
Inspections) purpose of each component of the machine as wells training in problem establishment phase of the
solving skills such as the Cause & effect and 5 whys. initial schedule a check and the
 We then have the operators re-inspected the machines with their new-found time needed for its
knowledge and highlighted new problems discovered in much the same way implementation.
that we did in step one.

5 Conduct  With what they have learned in stage 4 the operators modified the standards
Autonomous and instructions that they put in place for the first three stages of autonomous
Inspections maintenance to streamline and improve their Maintenance tasks.
 The tasks at this stage are also compared and rationalized with the
maintenance departments own maintenance schedules allowing tasks to be
allocated correctly and prevent duplication of effort.

6 Implement Visual  Provides Green/Red marks on Pressure gauges, oil level indicators.
Maintenance  stickled JH stickers that what to clean by which Tool
Management  Fix Machine area Dashboard which Displays all the details regarding that
 Highlight the direction of flow of fluids through pipe work.
 highlighted “safe” and “normal” operating values on gauges and sight glasses
in green and undesirable readings in red

7 Continuous  Repeated and improved on all that we have found and done in the previous
Improvement stages to continually improve and reinforce what done with autonomous
(KAIZEN) maintenance
 Team leaders, managers and maintenance technicians audited the work done
by the operators on a regular basis and both congratulated the operators on a
job well done and to give them the benefits of their knowledge.