Autonomous Maintenance and Focused Improvement
This audit serves as requirement to ensure alignment to JIPM standards and also for progression in the TPM cluster.
AUTONOMOUS MAINTENANCE STEP 1
The purpose of this audit is to ensure the Step 1 requirements of Autonomous Maintenance are being fulfilled. The requirements have been cross referenced with the Japan Institute of Plant Maintenance excellence award criteria.
Rating Scale: major deviation or more = 0, minor deviation= 1, meet expectations =2, exceeding expectations = 3, superior=4
STEP 1 AM DOCUMENTATION
REQUIREMENT / SCORE / RESPONSIBLEOne-Point Lessons: All one point lessons for the model area are to be completed in line with the JIPM Standards for hard to access, clean, inspect and lubricate. One-point lessons for safety aspects to be completed as well for the model area. One point lessons linked to the cleaning instruction where required for difficult elements are also a requirement. Register of reference numbers for 1 Point Lessons to TPM documentation must also be checked. / Autonomous Maintenance Pillar Head
Sources and type of contamination: A detailed study with required process sheets for the sources of contamination and the type of contamination. Problem solving documentation may be required for sources that are undefined. / Autonomous Maintenance Pillar Head
Cleaning Map: Detailed schematic of the model area equipment outlining points for cleaning, cleaning agents and referencing one-point lessons where required in the document. / Autonomous Maintenance Pillar Head
Cleaning Standard Operation Sheet with time study (standard time): Detailed step by step process sheet that allows operators to follow the instructions for cleaning according to the pre-defined cleaning standards. This will require the maintenance team to determine with production the cleaning operations, equipment required and the iterative steps to ensure compliance to safety regulations. / Focussed Improvement and Autonomous Maintenance Team. Ownership should reside with production once maintenance has defined the cleaning specifications.
Training and Development Matrix: Who has been trained, what is their level of competence towards TPM? The matrix should follow a competency check process and audits should allow for these checks to occur spontaneously / Autonomous Maintenance Pillar Head
Visual Board Institutionalisation: The visual board should serve as the audit hub. All requisite documents should be presented close to the line for frequent team discussions. This is critical for both pillars and requires a properly specified board that draws the attention of the floor visually. The team structures should be included as well. 1S and 2S Audits to be included. / Steering Committee
Evidence requirements must be sought for each point to ensure the documentation is in use and activities.
STEP 1 AM PRACTICE EVIDENCE
REQUIREMENT / SCORE / RESPONSIBLECleaning Exercise: Cleaning exercise is being adhered to in line with the cleaning instruction for the area/equipment. / Autonomous Maintenance Pillar Head
Knowledge Test 1 Pillar Heads or Shop Floor: What are the purposes of 1 point lessons? Training and development as well as detailed instruction to avoid error / Autonomous Maintenance Pillar Head/Shop Floor
Knowledge Test 1 Pillar Heads: Explain the measure for TPM Implementation. Overall equipment effectiveness / Autonomous Maintenance Pillar Head
Explain why the initial cleaning exercise is performed daily? As a mechanism to inspect and ensure equipment functioning. / Autonomous Maintenance Pillar Head
Visual Advice:Area standards provided with photos of what the area should look like complete with labelling, markings etc. / Autonomous Maintenance Pillar Head
Tag Register with Tag Count tracked over time:Tags are tracked. Dates for the tagging register must be validated to ensure daily checks with comments. Online registers may be provided with comments. / Red Tags – AM Pillar Head and White Tags – FI Pillar Head
Preparation of tools: Organisation evident of tools and production items in use as per agreed standardised defined through the sorting process / Autonomous Maintenance Pillar Head
Lists of hard to Clean, Lubricate, Inspect and Tighten are evident and available on the visual boards with reference to one point lessons: Detailed aspects to be covered by 1 point lessons. / Autonomous Maintenance Pillar Head
FOCUSSED IMPROVEMENT STEP 1-7
FOCUSSED IMPROVEMENT AUDIT
REQUIREMENT / SCORE / RESPONSIBLEKaizen A3 Summary Sheet: A company specific Kaizen A3 sheet may be developed (exampled can be found in the CII reference manual for Kobetsu Kaizen).Inclusion of the benefit, process and problem and outcome are imperative / Focussed Improvement Pillar Head
Stepped FI plan with a list of all projects: A detailed list of projects, expected completion date, responsible parties / Focussed Improvement Pillar Head
Visual Board Update: All projects presented onto the visual board and tracked as per the weekly meetings. Team structures. / Focussed Improvement Pillar Head
Evidence of 7 QC tools: Ishikawa, Cause and Effect Matrix, FMEA, Control Charts, Run Charts for improvement tracking / Focussed Improvement Pillar Head
Training and Development Matrix: Who has been trained, what is their level of competence towards TPM? The matrix should follow a competency check. / Education and Training Pillar Head
STEERING COMMITTEE REQUIREMENTS
REQUIREMENT / SCORE / RESPONSIBLE
Declaration:A company communication stipulating the objectives and commitment to TPM. / Focussed Improvement Pillar Head
FI and AM Team Structures: Officiated organograms outlining team structures for the AM and FI piilars. / Focussed Improvement Pillar Head
KPI’s: All projects and training are required to have KPI’s linked to a master KPI allocation. These are then cross referenced with Kaizen events and Am activities. / Focussed Improvement Pillar Head
TOTAL SCORE :
PERCENTAGE :
RESULT :
COMMENTS
AUDITORS:
PILLAR HEADS
STEERING COMMITTEE TEAM:
TPM STEP 1 AUDIT / 1