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Autonomous
Maintenance
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Learning Objectives
1. Understand the key concepts of TPM and AM activities
2. Learn how to implement the AM activities, step by step
3. Learn how to use activity boards, meetings and one-point lessons
to promote TPM goals
4. Learn how to measure and audit AM activities and performance
5. Familiarize with the JIPM TPM excellence criteria for AM
6. Understand the critical success factors in sustaining AM activities
on the shopfloor
NOTE: This is a PARTIAL PREVIEW.
To download the complete presentation, please
visit: https://www.oeconsulting.com.sg

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Contents
1. Overview of TPM
2. Introduction to AM
3. Tools of AM
4. How to Implement the Seven Steps of AM: The Step by Step
Approach
5. Measuring & Auditing AM Activities
6. JIPM TPM Excellence Criteria for AM
7. Sustaining AM

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Machine Failures Have Many Hidden Causes
Failure
Loosening
Contamination
Corrosion
Leaks
Flaws
Deformation
Vibration
Cracks
Backlash
Improper
Temperature
Wear
Less
Visible
Visible
Failure is what we
see but is only the
tip of the iceberg
Minor machine
defects are
generally unnoticed
but are the cause of
almost all machine
failures

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What is TPM?
Total Productive Maintenance (TPM) is a method to
achieve maximum equipment effectiveness through
employee involvement
Management + Operators + Maintenance

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TPM Drives the “Three Evils” Out of the Workplace
Use TPM to eliminate difficulty, dirt and danger from the workplace
and create a working environment where it is easy to work.
Dirt
Difficulty Danger
Difficult tasks are hard to
do right because they are
so fatiguing.
Dirt is more than just
unsanitary. If neglected,
it can cause equipment
to break down and create
unsafe conditions.
Such conditions create a
dangerous workplace
and sooner or later will
cause major accidents.
Source: Adapted from TPM for Every Operator

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TPM Goals
§ Maximize equipment effectiveness
§ Zero breakdowns
§ Zero defects
§ Zero accidents
Zero waste!

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Objective: To place responsibility for routine maintenance
(e.g. cleaning, lubricating, and inspection)
in the hands of operators
Autonomous Maintenance
§ Benefits:
- Gives operators greater “ownership” of their equipment
- Increases operators’ knowledge of their equipment
- Ensures equipment is well-cleaned and lubricated
- Identifies emergent issues before they become failures
- Frees maintenance personnel for higher-level tasks

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AM is a Paradigm Shift
Old Attitude TPM Attitude
I use I maintain &
I fix
We maintain
Maintenance Operator Maintenance
Operator

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AM Activities Improve Equipment Efficiency & Upgrade
Operator Skills
Correction &
Restoration
Traditional Culture
Operator’s
Knowledge
Detect
Abnormalities
Cleaning is
Inspection
Visual
Workplace
Learn Equipment
Structure &
Function
TPM/Lean Culture
Autonomous
Maintenance
Equipment
Maintenance
Skills
Maintain Optimum
Equipment
Conditions
Standards &
Inspection
Autonomous
Management
Equipment-
focused
Operator-
focused

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Accidents Occur When Unsafe Conditions Combine With
Unsafe Behavior
Unsafe condition Unsafe behavior
Unsafe conditions are physical
problems such as missing
guardrails or inadequate safety
devices.
Unsafe behavior refers to actions
resulting from a failure to stick to
specified standards.
In TPM, safety activities are a perfect match for the
development of Autonomous Maintenance.
Source: Adapted from TPM for Every Operator

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Goals of Autonomous Maintenance
Goals of
Autonomous
Maintenance
Prevent
Equipment
Deterioration
Equipment
Restoration &
Proper
Management
Establish Basic
Conditions

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4
3
Set Optimum
Equipment Conditions
2
1
Correct & Restore
Abnormalities
Detect
Abnormalities
Four Equipment-related Skills
for Operators
Maintain Optimum
Equipment Conditions

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3 Key Tools for AM Team Activities
Activity
Boards
Meetings
One-Point
Lessons

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Example: AM Activity Board
Step 2: Sources of Contamination
People Results
Definition
Team Mission
Layout of Line &
Identified Important
Areas
Safety Hazard
Contamination
Hard-to-reach
Main Failure
• Team Name
• Members
Line
• Mission
• Objectives
Activity & Findings
Step 1: Initial Cleaning
Pictures Before After
Tag List Production Maintenance
Tag Movement
Actual Tags
Display actual findings from
Initial Cleaning such as trash,
unnecessary items, dust and
other contamination
Explain and show Focused
Improvement activities
for sources of contamination
One-Point-Lessons
Team

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Example: One-Point Lesson
Dept.
Manager
Super-
visor
Team
Leader
Created
by
Basic
Knowledge
Improvement
Example
Trouble
Cases
Date
Executed
Instructor
Trainee
David
Classification
Tom
Action
History
Mark Paul
Subject
Compressed Air Usage
For Line #1 & 2
TPM One-Point Lesson
No.
Date of
Creation
November, 2010
DL4301
1. Compressed
Air may only be
used on the
Dribbler Scale
ONLY
2. Scale Area is
currently Hard-To-
Reach and may
cause variable
weight if not
cleaned
1
2
Don’t Make A Bigger Mess !!!
One-Point Lesson is a tool
with the following
characteristics:
Ø One sheet…
Ø To share the results
of autonomous study…
Ø For 5-10 minutes
Contents can be knowledge and
skills of:
Ø Equipment
Ø Safety
Ø Operation process
Ø Task

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7 Steps of Autonomous Maintenance
Draw Up Cleaning & Lubricating Standards
3
Eliminate Problem Sources & Inaccessible Areas
2
Clean and Inspect
1
Conduct General Inspections
4
Implement Autonomous Equipment Management
7
Standardize through Visual Workplace Management
6
Conduct Autonomous Inspections
5

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Two Approaches for Correcting Equipment Problems
Cleaning / Inspection
Discovery of
abnormality or
slight defect
Instant
Maintenance
Requested Maintenance
The operator immediately
restores or improves upon
the abnormality or slight
defect.
If unable to immediately
restore or improve upon the
abnormality or slight defect,
the operator requests help
from the maintenance
department.
Correcting
Equipment
Problems
Source: 5S for Operators, Productivity Press

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Step 1 – Clean and Inspect
§ Eliminate all dirt and grime on the machine, lubricate and tighten
bolts
§ Find and correct problems
§ Implement the Activity Board and the 4Ms
§ Address operators’ questions during education process
§ Develop countermeasures to misoperations as early as possible
Eliminate all sources of dirt and grime on the machine,
lubricate, tighten bolts, and find and correct problems

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Example of Tagging
During initial cleaning
Afterwards –
Everyday process
Tag is removed only after the
repair is made

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Monitoring Tags
0
50
100
150
200
250
J
u
l
y
A
u
g
u
s
t
S
e
p
t
e
m
b
e
r
O
c
t
o
b
e
r
N
o
v
o
m
b
e
r
D
e
c
e
m
b
e
r
Number
of
Tags
Tags
Issued
Tags
Restored
June

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Dept. / Line : Bldg Y Mach. ID : Date: 4/28/2004
S D W M
Cleaning
1 Water trap Empty bowl Open valve Cloth 1 X Operator
This is the maximum level for water in the bowl.
Open valve at bottom to release water, wipe up with clean cloth.
Insert
Picture
Here
Tools
T
(Min)
Person
Resp.
Autonomous Maintenance
Routine Cleaning, Inspection, & Lubrication Standard
Freq
Diagram No. Item Criterion Method
Area : Bag Printer Tag # :
Example: Establish Cleaning Standard

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Step 5 – Conduct Autonomous Inspections
§ Prepare standard check sheets for autonomous inspections
§ Define autonomous chart / schedule for each operator
§ Carry out the inspections
§ Use new methods of cleaning and lubricating
Prepare standard worksheets for autonomous
inspections. Carry out the inspections.

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Maintenance
Activities
Breakdown
Maintenance
Predictive
Maintenance
Preventive
Maintenance
Routine
Maintenance
Robustness Improvement
Effective And Appropriate Repairs
Trends Measurement And Control
Condition Based Servicing
Building Of Programs
Time Based Applications
Cleaning - Refurbishing
Lubrication & Tightening
Daily Inspection
Daily Equipment Care
Production Maintenance
Example: AM – Who Does What?
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔

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Visual Control Example: Lubrication
Mark lubrication points
with a label that
identifies the proper
grease quantity and
frequency. To ensure
that the correct lubricant
is used, consider also
color coding the lube
point label to match the
label on the appropriate
grease gun.
Source: Brady 50 Lean Visuals Pocketbook

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Visual Control Examples
Gage labels
Adding a simple gauge label enables any
employee to easily detect abnormalities at
a glance and at a distance. Without the
label, only a trained inspector would know
if the temperature or pressure setting is
correct.
Oil level indicators
Placing a green and red striped label
behind the oil sight tube helps
operators quickly detect when oil levels
are too high or too low.
Source: Brady 50 Lean Visuals Pocketbook

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Ideas for Visual Control
§ Indicate V-belt / chain type
§ Indicate V-belt / chain direction of rotation
§ Install peep window for checking belts
Drive Systems
Drive tension guides
Drive tension guides help operators
inspect for proper tension on the
drive system. Using red and green
color blocks, these visuals indicate
when a chain or belt needs to be
tightened or replaced.

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Three Important Reasons for Audits
1. To determine whether each step has been fully implemented
2. To provide feedback to teams on the strengths and weaknesses of
their activities
3. To clarify what needs to be achieved and how best to achieve it

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Example of Audit Checklist for Step 1 AM Activities

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Operational Excellence Consulting is a management training and consulting
firm that assists organizations in improving business performance and
effectiveness. Based in Singapore, the firm’s mission is to create business
value for organizations through innovative design and operational excellence
management training and consulting solutions. For more information, please
visit www.oeconsulting.com.sg