The 7 Steps of Autonomous Maintenance

7
6 5
Autonomous management Standardize and sustain Maturity phase

Conduct autonomous inspection Conduct general inspection training

Develop ment phase

3 2
1 0

Set provisional standards for cleaning, checking and lubrication

Take countermeasures for contamination sources

Start up phase

Conduct initial cleaning and inspection

Education and training

Nakajima

Step 1, Conduct Initial Cleaning and Inspection TPM Team

Implementation, de-tagging, photo, documentation FuguaiTagging, photo, FTag register

Planning With Risk Assessment

Action

Next step

Audit

Deploy to other area

Step 1, Conduct Initial Cleaning and Inspection

Step 1, Conduct Initial Cleaning and Inspection

Step 2, Countermeasures for contamination sources

Initially, cleaning takes long time

Difficult to access No place for standing Inspection is blocked by wiring and piping

TPM Team

Action

1.

2.

Difficult to access area Sources of contamination

Water, Oil, Debris, Powder, Dust, etc Debris collection Increase number of cleaning

Step 3, Provisional Standards, Part 1

Model line

New group Deploy to all equipments

Inspection window Difficult for lubrication Cleaning more than 5 minutes Difficult for inspecton Ineffective tightening Lubrication causes dirt

Step 3 Provisional Standards, Part 2

Review improvement results Lubrication Management Develop new lubrication test point Conclude cleaning and inspection provisional standards

Learning from Step 1,2

Number of Lubrications, Lubricants visual Management

Discussion with Maintenance and Engineering

Use as standard time for manpower allocation

Draft cleaning and inspection (Lubrication) Provisional Standards

Use as standard time for manpower allocation

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

Ref. Borris

Training Matrix