7 Steps for Evolving Autonomous Maintenance
Step Name
1 Initial clean-up
2 Measures against Sources
3 Formulation of clean-up
and lubrication standards
4 Overall inspection
5 Autonomous check-up
6 Orderliness and tidiness
7 All-out autonomous
management
Description
All-around clean-up of dust and dirt, centering on equipment proper, and
implementation of lubrication, and machine parts adjustment; discovery and
repair of malfunctions in equipment
Prevent causes of dust and dirt and scattering, improve places which are
difficult to clean and lubricate and reduce the time required for clean-up and
lubrication.
Formulate behavioral standards so that it is possible to steadily sustain clean-
up, lubrication and machine parts adjustment in a short period (Necessary to
indicate a time frame-work that can be used daily or periodically)….
Training in check-up skills through check-up manuals; exposure and restoration
of minor equipment defects through overall check-ups
Formulation and implementation of autonomous check-up sheets
Standardize various types of on-the job management items and devise
complete systematization of up-keep management.
• Standards for clean-up, check-ups and lubrication
• Standards for physical distribution in the workplace
• Standardization of data records
• Standardization of die management, jigs and tools
Development of corporate policies and goals, and making improvement
activities routine : Steadily record MTBF analysis, analyze these, and carry out
equipment improvements
 7 Types of Abnormalities
1. Minor Flaws
2. Unfulfilled Basic Conditions
3. Inaccessible places
4. Contamination sources
5. Quality Defect Sources
6. Unnecessary and non-urgent items
7. Unsafe places
 1. MINOR FLAWS
Contamination Dust, Dirt, powder, oil, grease, rust, paint
Damage Cracking, crushing, deformation, chipping, bending,
Play Shaking, falling out, tilting, eccentricity, wear, distortion,
corrosion,
Slackness Belts, Chains

Abnormal Unusual noise, overheating, Vibration, strange smells,

Phenomenon discoloration, incorrect pressure or current
Adhesion Blocking, hardening, accumulation of debris, peeling,
malfunction
 2. UNFULFILLED BASIC CONDITIONS
Lubrication Insufficient, Dirty, Unidentified, unsuitable, Leaking

Lubrication Supply Dirty, damaged or deformed lubricant inlets, faulty

lubricant pipes

Oil level gauges Dirty, Damaged, leaking, No indication of correct level

Tightening Nuts and Bolts slackness, Missing, Cross-threaded,

Too long, Crushed, Corroded, Unsuitable washers,
wing nuts on backward
 3. INACCESSABLE PLACES
Cleaning Machine construction, Covers, Layout, footholds, Space

Checking Construction, Covers, Layout, footholds, Instrument position

and Orientation, Operating – Range display

Lubricating Position of lubricant inlet, construction, height, footholds,

lubricant outlets, space

Tightening Covers, Construction, Layout size, Space

Operation Machine layout, Position of valves, Switches and leavers,

Footholds

Adjustment Position of pressure gauges, thermometers, flow meters,

moisture gauges, vacuum gauges, etc.
 4. CONTAMINATION SOURCES
Product Leaks, Spills, Spurts, Scattering, Overflow
Raw materials Leaks, Spills, Spurts, Scattering, Overflow
Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils,
etc.

Gases Leaking compressed air, gases, steam, vapors, exhaust

fumes, etc.

Liquids Leaking water, Hot, Cold, half finished products, Waste

water, Leaking supply lines etc.

Scrap Flashes, cuttings, packaging materials, and non

conforming products.

Others Contaminants by people & Forklifts, Infiltration through

cracked walls, broken windows etc.
 5. QUALITY DEFECT SOURCES
Foreign Matter Dust, Rust, powder, chips, moisture, wire scraps, wood
pieces, paper pieces, stones etc.

Shock Dropping, Jolting, collision, Vibration etc.

Moisture Too little or Too much, infiltration
Gain Size Abnormalities in screens, Compressed air separators,
centrifugal separators,

Concentration Inadequate warming, heating, compounding, mixing,

evaporation, stirring etc.

Viscosity Inadequate warming, heating, compounding, mixing,

evaporation, stirring etc.
 6. UNNECCERY AND NON-URGENT ITEMS
Machinery Pumps, fans, compressors, columns, tanks etc.
Piping equipment Pipes, hoses, ducts, valves, dampers etc.
Measuring Temperatures, pressure gauges, vacuum gauges,
instruments ammeters etc.
Electrical equipment Wiring, piping, power leads, switches, plugs etc.

Jigs & Tools General tools, cutting tools, jigs, molds, dies, frames etc.

Spare parts Standby equipment, spares, permanent stocks, auxiliary

materials, etc.

Makeshift repairs Tape. String, wire, metal plates etc.

 7. UNSAFE PLACES
Floors Unevenness, cracked, holes, projections, peeling, wear of steel
chucker plates, slipping.
Steps Too steep, irregular, slipping, missing handrails, etc.
Lights Dim, out of position, dirty or broken covers, no explosion
proofing, etc.
Rotating Displaced, fallen oil or broken covers, not safe for emergency,
machinery missing emergency stop devices
Lifting Wires, hooks, brakes and other parts of cranes and hoists etc.
Devices
Others Special substances, solvents, toxic gases, insulating materials,
danger signs, protective clothing etc.
EXAMPLE OF ABNORMALITY
( LOOSE FITTINGS )
EXAMPLE OF ABNORMALITY
( LEAKAGES )
 HARMFUL EFFECTS OF INADEQUATE CLEANING

Failure Dirt and foreign matter penetrates rotating parts, sliding parts, pneumatic
and hydraulic systems, electrical control systems and sensors etc.,
causing loss of precision, malfunction and failure as a result of wear,
blockage, frictional resistance, electrical faults etc.

Quality Defects Quality Defects are caused either directly by contamination of the
product with foreign matter or indirectly as a result of equipment
malfunction.

Accelerated Accumulated dust and grime make it difficult to find and rectify cracks,
Deterioration excessive play, insufficient lubricants, and other disorders, resulting in
accelerated deterioration.

Speed Losses Dust and dirt increase wear and frictional resistance causing speed
losses such as idling and under performance.
Points to be checked during
initial cleaning (Sample)
 Checkpoints for Nuts & Bolts

Slight Loose nuts & bolts, missing nuts & bolts

defects

Bolt length All bolts should protrude from nuts by 2-3 threads
Washers • Are flat washers used on long holes
• Are tapered washers used on angle bars & channels
• Are spring washers used for parts subjected to vibration
• Are identical washers used in identical parts

Fixing of • Are bolts inserted from below, are they visible from outside
nuts & bolts • Are devices such as limit switches fastened at least by 2 bolts
• Are wing nut direction clock wise
 Lubrication checkpoints
Lubricant • Are lubricant sores always kept clean, tidy, are 5S principles applied
storage • Are lubricant containers always capped
• Are lubricant type clearly indicated and is proper stock control practiced

Lubricant • Are grease nipples, speed reducer lubricant ports and other lubricant inlets
inlets always kept clean
• Are lubricant inlets dust proofed
• Are lubricant inlets labeled with correct type and quantity of lub.

Oil level • Are oil level gauges always kept clean, are oil levels easy to check
gauges • Is the correct oil level clearly marked
• Is equipment free of oil leaks, and oil pipes& breathers unobstructed

Auto Lub • Are Auto lubricating devices operating correctly & supplying correct quantity
Devices of lubricants

Lubricating • Are rotating, sliding parts, and transmission well lubricated

condition • Are the surroundings free of contamination by excess lubricant
 Transmission System checkpoints

V-Belts & • Are any belt cracked, swollen, worn out, or contaminate by lub.
Pulleys • Are any belts twisted or missing. Are any belts stretched or slack
• Are multiple belts under uniform tension and all of the same type
• Are top surfaces of belts protruding above the pulley rims? Are the
bottoms any pulley groves shiny (indicating a worn belt or pulley)
• Are pulleys correctly aligned

Roller • Are any chains stretched 9indicating worn out pins or bushings
chains • Are any sprocket teeth worn, missing or damaged
• Is lubrication between pins and bushings sufficient
• Are sprockets correctly aligned

Shafts, • Is there any overheating, vibration, abnormal noise due to excessive

Bearings & play, or lack of greasing. Are any keys or set bolts loose or missing
Couplings • Are any couplings misaligned or wobbling, Are any seals worn out

Gears • Are gears rightly lubricated with proper amount of lubricant.

• Are any teeth missing, damaged worn out or jammed
• Is there any unusual noise or vibration
 Hydraulic checkpoints

Hydraulic • Is there correct quantity & level indicated for fluid in the reservoir
Checkpoints • Is fluid of correct Temp. And is min & max for temp. indicated
• Is fluid cloudy (indicating air entrapment
• Are all fluid inlets & strainers clean, are any suction filters blocked
• Are any fluid reservoir breather filters blocked
• Are fluid pumps operating without any unusual noise or vibration
• Are hydraulic pressure correct, and are operating ranges displayed

Heat • Is any fluid or water leaking from fluid coolers or pipes

Exchangers • Are temp. differences between fluid & water inlets & outlets are
correct ? Are any tubes blocked

Hydraulic • Are there any fluid leaks ? Are hydraulic properly fastened?
Equipment • Are hydraulic devices operating correctly without speed loss or
breathing? Are hydraulic pressure correct? And all gauges working

Piping and • Are all pipes and hoses fastened tightly?

Wiring • Are there any fluid leaks? Are any hoses cracked or damaged?
• Are all valves operating correctly? Is it easy to see whether valves
are open or closed/ Are any pipes, valves unnecessary?
 Pneumatic checkpoints
FRLs • Are FRLs clean? Is it easy to see inside of them? Are they fitted right
way around?
• Is there sufficient oil. And are the drains are clear?
• Is the oil dip rate correct ?(approx 1 drop for every 10 strokes)
• Are the FRLs installed not more than 3 m from the equipment?
• Are the pressure adjusted to the correct value and operating ranges
are clearly indicated?

Pneumatic • Is compressed air leaking from pneumatic cylinders or solenoids?

Equipment • Are all pneumatic cylinders and solenoid valves firmly fastened?
• Are any pistons dirty, worn, damaged?
• Are the speed controllers installed right way around?
• Is there any abnormal sound or overheating of solenoid valves, and
are any lead wires chafed or trailing?

Piping and • Are there any places in pneumatic pipes or hoses where fluid is liable
Wiring to collect? Are all hoses and pipes clipped firmly in place?
• Are any hoses cracked, damaged, are there any air leaks?
• Are valves operating correctly and open and close position known
 Electrical Checkpoints
Control • Are the interiors of distribution boards, switch boards, and control
Panels panels kept clean, tidy, and well organized by the application of 5S
activities? Have any objects or flammable materials been left inside
• Is the wiring inside control panels in good condition? Are any wires
coiled or trailing?
• Are all ammeters and voltmeters operating correctly?
• Are any switches, bulbs broken? Do all switches work correctly?
• Are panel doors in good condition? Do they Open & close easily?
• Are there any unused holes? Are control panels water& dustproof?

Electrical • Are all motors free of overheating, vibration, unusual noise & smell
Equipment • Are al motor cooling fans and fins are clean?
• Are any bolts loose? Are pedestals free of cracks and damages?

Sensors • Are all manual switches clean and free of damages & excessive play
• Are all switches installed in the correct position
• Are the interiors of limit switches is clean? Are any wires coiled or
trailing?
• Are any limit switch dogs worn, deformed, or of the wrong shape?
 Electrical Checkpoints – Cont.
Sensors • Are all photoelectric switches and proximity switches clean and free of
excessive play?
• Are any sensors out of position? Are correct positions clearly
indicated?
• Are all lead wires un-chafed, and is insulation intact at entry points?

Switches • Are all switches installed in the correct position

• Are all manual switches clean and free of damages & excessive play
• Are emergency stop switches installed in appropriate locations and are
they in good working condition?

Piping and • Are any pipes, wires, or power leads loose or unsecured?
Wiring • Are any ground wires damaged or disconnected?
• Are any pipes damaged or corroded? Are there any bare wires or wires
with damaged insulation?
• Are any wires coiled on the floor or dangling overhead?
White tags for operators
Equipment Name ………………
Control No……………………..
Date of detection……………….
Detected by……………………..
Description of Minor defects
………………………………….
…………………………………..
………………………………….
Pink Tags to be attended by Maint.
Equipment Name ………………
Control No……………………..
Date of detection……………….
Detected by……………………..
Description of Minor defects
………………………………….
…………………………………..
………………………………….
 Abnormality - tag matrix

Abnormality
leads to
Abnormality
S
n
o Exact description of
location
 List of “Abnormalities” in the Equipment

Equipment Name : ______________________ Unit Name : ___________________________ No. : ______________

Why is it “Abnormality
Date of Why did it become
“Abnormality “Abnormality”? (What Contents of the tag” Planned Date of
No. Detec- Detector so? (What is the Executor
” Item will happen if it is left Countermeasures Classifica- Date completion
tion cause?)
as it is?) tion
 List of illustration of hard-to-access areas

Equipment Name : ______________________ Unit Name : ___________________________ No. : ______________

“Abnormality
Date of Items Cleaning
Detecto Contents of the tag” Planned Date of
No. Detec- Lubrication Difficult Portions Difficult State Executor
r Countermeasures Classifica- Date completion
tion Inspection
tion
C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I

C L I