AUTONOMOUS

MAINTENANCE
STANDARD TOOLS

STRICTLY CONFIDENTIAL

WCM CENTRAL TEAM

Autonomous Maintenance
Tag
Name / personal.nn

STEP 0
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5

Date

......./..../.....

Shif t

..

N. machine:

Type of abnorm ality (m ark by cross)

A Water leakage

H Missing cover

B Oil leakage

C Air leakage
D Disorganization
vzduchu,syen/ cables
E Lack of space
F Dust, pollution

L Missing part
M Overplus

Lack of lubrication
sousti
J Vibration / noise
K Wear / damaged part

G Lack of instruction (visualization)

O Other

STEP 6
STEP 7
S
CD
FI
AM

materilu

Part of the machine ..

Details about abnormality:
..
..
..

Classification of tag:
S

ENV

QM EEM

PD

WO

AM

PM

Responsibility:
AM

PM

PM

COUNTERMEASURE DONE:

QC

NAME

L&CS
EEM/EPM
PD

DAY:.../...../..
SIGN...
DETAILS OF COUNTERMEASURE
.
.
.

ENV

Autonomous Maintenance
Tag register
TAG REGISTRATION
284
Tag n

STEP 0

Tag
Classification

284

Issued
Date

Week

Name

Machine /
Area

Type

Component

Anomaly description

Responsible
Due date
Responsible for
for
for
countermeasure
countermeas
counterm
- PERSON
ure - AREA
easure

0
Countermeasure description

584

Actual
Actual date
date for
for
counterme countermea
asure
sure [Week]

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

-5686 - 1900

10

-5686 - 1900

-5686 - 1900

11

-5686 - 1900

-5686 - 1900

12

-5686 - 1900

-5686 - 1900

13

-5686 - 1900

-5686 - 1900

14

-5686 - 1900

-5686 - 1900

15

-5686 - 1900

-5686 - 1900

16

-5686 - 1900

-5686 - 1900

17

-5686 - 1900

-5686 - 1900

18

-5686 - 1900

-5686 - 1900

19

-5686 - 1900

-5686 - 1900

20

-5686 - 1900

-5686 - 1900

21

-5686 - 1900

-5686 - 1900

22

-5686 - 1900

-5686 - 1900

23

-5686 - 1900

-5686 - 1900

24

-5686 - 1900

-5686 - 1900

25

-5686 - 1900

-5686 - 1900

26

-5686 - 1900

-5686 - 1900

27

-5686 - 1900

-5686 - 1900

28

-5686 - 1900

-5686 - 1900

29

-5686 - 1900

-5686 - 1900

30

-5686 - 1900

-5686 - 1900

31

-5686 - 1900

-5686 - 1900

32

-5686 - 1900

-5686 - 1900

33

-5686 - 1900

-5686 - 1900

34

-5686 - 1900

-5686 - 1900

CD

35

-5686 - 1900

-5686 - 1900

36

-5686 - 1900

-5686 - 1900

37

-5686 - 1900

-5686 - 1900

FI

38

-5686 - 1900

-5686 - 1900

39

-5686 - 1900

-5686 - 1900

40

-5686 - 1900

-5686 - 1900

41

-5686 - 1900

-5686 - 1900

42

-5686 - 1900

-5686 - 1900

43

-5686 - 1900

-5686 - 1900

44

-5686 - 1900

-5686 - 1900

45

-5686 - 1900

-5686 - 1900

46

-5686 - 1900

-5686 - 1900

47

-5686 - 1900

-5686 - 1900

48

-5686 - 1900

-5686 - 1900

49

-5686 - 1900

-5686 - 1900

50

-5686 - 1900

-5686 - 1900

51

-5686 - 1900

-5686 - 1900

52

-5686 - 1900

-5686 - 1900

53

-5686 - 1900

-5686 - 1900

54

-5686 - 1900

-5686 - 1900

55

-5686 - 1900

-5686 - 1900

56

-5686 - 1900

-5686 - 1900

57

-5686 - 1900

-5686 - 1900

58

-5686 - 1900

-5686 - 1900

STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
STEP 7
S

AM
PM

QC
L&CS
EEM/EPM
PD
ENV

25/12/2008
Solved

Spare parts /
Equipment

ID Warehouse

Autonomous Maintenance
AM
Autonomous
Maintenance

CHECK-LIST STEP 1

PLANT

####

AREA

####

INTERNAL AUDITORS

####

DATE

CHECK-LIST

TOTAL

SCORE

REMARKS

RATING STANDARDS
Rating

TOPIC

STEP 0
STEP 1

Participation and
management of the
project

STEP 2
STEP 3
STEP 4
STEP 5
STEP 6

Tidiness and
cleanliness around
the machine

Sources of dirt and

areas difficult to
access

CD

Cleaning of the
body of the
machine
and tools

FI
AM

Electrical parts
(specific checks)

PM
L&CS

2-3

1,02

Has the board been updated and is its purpose clearly

understood?

0-1

1,03

Are objectives and results indicators displayed, KAI's & KPI's?

1,04

Has a general activity plan been drawn up (duration of the

steps, improvement, actions etc.) and is it displayed?
MASTER PLAN

EEM/EPM
PD
ENV

Self Evaluation

Rating criteria
H

L (low )

M (medium)

H (high)

4-5

practically no understanding
or participation

only some of the members of

the team

all, including technicians, take

action according to needs

2-3

4-5

it is not updated, no-one

reads it

updated but not read

It is a tool of communication

1-2

do not exist

exist but are not displayed

are displayed on the board

does not exist

exists but is not displayed

are displayed on the board

causes and effects are

analyzed only by the area
supervisor

causes and effects are

analyzed by the team

exist but is not followed

exists and it is followed

1,05

Are irregularities and problems suitably tagged?

1-2

no, the repairs are carried out

directly

1,06

Is there a plan to close tags and is it followed?

1-2

does not exist

1,07

Are stoppages for AM activities planned and followed?

1-2

1,08

Have tasks been assigned (who does what, when and how)?

1-2

1,09

Are all tools/equipment present, functioning, tidily and correctly

positioned?

1-2

1,10

Are there any residues, scraps of paper, cigarette ends, bags

or plastic cups scattered in the work area?

Some scheduling exists but

decisions are taken at the last
there is not a good managed
moment, not planned
plan, results are limited
exists but is not complied
does not exist
with
no indication of place,
precise indications but
scattered
scattered and damaged
objects

activities are scheduled and

followed properly
everyone knows what to do,
how to do and does it
correct indications without
damage

visible untidiness

ok

Are all nameplates visible?

Is there any grime, dust, loose covers on safety guards?
Are hoses and cables clean and tidy?
Is there any dust or grime around the machine, or accumulation
of dust on the top of the machine?
Are there obsolete parts/tools/equipment/etc that should not be
in the area still there?

0
0
0

1
1
1

difficult to read
present
no, in an evident manner

easy to read
none
ok

yes

no

yes

no

1,16

Are there labels showing expired date?

yes

no

1,17

Are spaces reserved for non conforming material clearly

identified?

not clearly identified

1,18

Are there dirty areas and have the sources of dirt been traced?

0-1

2-3

4-5

yes, they have been identified

but are not recorded

recorded but incomplete

complete, detailed list

1,19

Is there a list of difficult access zones?

0-1

2-3

4-5

does not exist

exists but is inaccurate

the list is complete and

detailed

1,20

Is there any grime, dust, dirt, oil or process waste or foreign

objects, etc. in all the area?

0-1

2-3

4-5

Some areas that contain dirt

Perfectly clean

1,21

Are there any loose nuts and bolts?

1-2

some loose screws/bolts

no loosening

1,22

Are there any foreign objects on the body of the machine?

0-1

2-3

1,23

Are there any worn parts, vibrations, irregular temperatures?

Dirt is evident in the whole

area
some missing; the paint
indicator is missing
presence of superfluous
objects, scattered objects
some visible irregularities

1,24

Are there any indicator lights/bulbs not working?

1-2

more than 2 not working

more than 1 not working

All are working

1,25
1,26

Are the motor and filter covers clean?

Are the limitswitches and photocells clean?

0
0

1-2

3
1

dirty but not clogged

clean
clean

1,27

Is the control panel clean?

1,28

Are cables and cable covers clean?

completely clogged
practically covered in dirt
presence of superfluous
materials
parts uncovered or pipes not
securely fastened

1,29

Are there any broken, superfluous, missing, loose parts?

1,2

some parts broken or missing

some superfluous or loose

parts

no loosening or absences

some visible irregularities

some minor irregularities

no irregularities

1-2

broken, dirty and inefficient

no range

clean, efficient and with range

dirt inside and outside

ok, but approximately

thoroughly cleaned inside and

outside

1-2

major irregularities

minor irregularities

no irregularities

some visible irregularities

some minor irregularities

everything ok

many shortages of oil

can be partially noted

1,11
1,12
1,13
1,14

1,32
1,33
1,34

Lubrication system
(specific checks)

0-1

1,30

Hydraulic, coolant
and pneumatic
systems (specific
checks)

1,01

1,31

QC

CHECKS
Has the AM method been understood and do operators
participate in the activities?

1,15

STEP 7
S

No.

Are there any worn parts, parts that vibrate, with irregular
temperatures?
Are gauges clean and working? Is the working range shown and
are the gauges within the range?
Are oil level readouts clean?
Are there any irregularities in the oil (type, contamination,
levels)?
Are there any broken, superfluous, missing, loose, worn parts,
etc.?

1,35

Is there a shortage of oil in moving parts?

1,36

Are there sufficient quantities of lubricant?

1,37

Are all tank and cap covers in place?

1,38
1,39

Are there leaks, stains, dirt on supply pipes?

Are the guide scrapers efficient?

0
0

1,40

Has this checklist been used by team to self evaluate the step?

3
3

no top-up; level of tank is

below min.
some parts without cover or
broken
leaks and dripping of oil
broken or lack

no

1
1-2
1-2

are visible

presence of superfluous
objects but arranged tidily
some minor irregularities

no unnecessary objects
no fault

clean
no irregularities

levels above standard

sufficient lubrication of all

parts
regular top-ups; level within
standard
cover present and efficient

minor leaks of oil

not efficient

no leaks
yes
Yes

Autonomous Maintenance
AM
Autonomous
Maintenance

CHECK-LIST STEP 2

PLANT

####

AREA

####

INTERNAL AUDITORS

####

DATE

CHECK-LIST

TOTAL

SCORE

REMARKS

RATING STANDARDS
Rating

TOPIC

STEP 0

(1) Maintenance of
cleanliness of
machine body and
tools.

STEP 1
STEP 2
STEP 3

(2) Actions to
eliminate causes of
problems.

STEP 4
STEP 5
STEP 6

No.

CHECKS

2,01

Are the following conditions maintained:

(1) Cleanliness of machine body?
(2) Cleanliness of instrumentation and of auxiliary parts?
(3) Lubrication?
(4) 5S around the machine?

0-1

2-3

4-5 Nothing has been done

Corrective actions have been

taken. The results have not
been checked

Corrective actions have been

taken. The results have been
checked

2,02

Is the tagging system managed in a continuos and

timely fashion?

0-1

2-3

4-5 In random manner

Fairly regularly.

Always

2,03

Have actions been taken to solve the problems indicated

by the tags?

0-1

2-3

4-5 Nothing has been done

Corrective actions have been

taken. The results have not
been checked

Corrective actions have been

taken to reduce cleaning,
inspection and lubrication
time. The results have been
checked

2,04

Do programs exist for the actions identified but not yet

carried out?

1-2

3-4 Do not exist

Exist, but are not complied

Exists and is complied

2,05

Are there still AM tags with causes not yet identified?

0-1

2-3

4-5 > than 3

< than 2

Some, depend on technical

times

0-1

2-3

4-5 Very few

Yes, without defining priority

Yes and in priority manner

0-1

2-3

4-6 Very few

Yes, without defining priority

4-5 Nothing has been done

Corrective actions have been

taken. The results have not
been checked

Yes and in priority manner

Efficient, simple, inexpensive
and easily removed devices
have been constructed. The
results have been checked

2,06
2,07

Have actions been identified to eliminate zones

inaccessible for cleaning?
Have sources of dirt been eliminated?
Have guards, chutes, etc. been introduced to restrict
dirt?

2,08
(3) Activities for
elimination of
Has the situation been improved to facilitate:
zones inaccessible
for cleaning.
2,09 (1) cleaning of equipment?

STEP 7

Rating criteria

2,10
2,11

(2) removal of the various types of covers?

(3) workplace cleaning?

2,12

S
CD
FI

(5) Zone around the

machine.

AM
PM

QC

2-3

1-2

No proposal

No method, random manner

0
0

1-2
1-2

3
3

No
No
Not defined, each operator
has his/her own tools and
manages these personally

By chance
By chance

There are no indications

Not on a routine basis

There are no indications

EEM/EPM
PD
ENV

Interventions with reduced

effort and with method
Yes
Yes
Defined, rational and known to
all

0-1

2-3

4-5 They are scattered

Not on a routine basis

Have tools, instruments and equipment been identified?

1-2

3-4 They are scattered

They are tidy but without

identification

2,17

After AM tagging, has the problem been analyzed with

the contribution of all area personnel (e.g. all shifts)?

0-1

2-3

4-5 Never

Occasionally

Always

2,18

To improve problem solving, have the causes been

analyzed and is data systematically checked?

0-1

2-3

4-5 Are not known

Afterwards

Often

2,19

Do all members of the AM team participate in carrying

out the modifications highlighted by the fault analysis?

0-1

2-3

4-5 No

Only part of the team

The entire team

2,20

Has documentation of the action taken been issued?

0-1

2-3

4-5 Has not been done

Has been carried out but is

not shown on the board

All improvements are

displayed on the board.
Application of these to
existing machines and on
those that will be purchased
is facilitated

2,21

Are indicators KPI's and KAI's showing improvement?

Are the codes of the product used displayed close to

each lubrication, supply or top-up point?

2,14

Does each storage area, clearly identify the product in

which it is contained?

2,15

Have direct materials PROCESSED/TO BE

PROCESSED, OK/Not-OK been defined and separated?

2,16

2,22
(7) Standards
2,23
Self Evaluation

H (high)

The identification code of the

product to be used is
indicated close to each point
(label or marked with paint)
Each container has its own
label
Positions are defined and
visible. Separation between
OK and Not-OK products is
clear
They are tidy and complete
with identification labels

2,13

(6) Management of
the project.

L&CS

M (medium)

0-1

Has a suitable place been defined for cleaning tools?

(4) Identification of
consumables.

L (low)

2,24

Are there a temporary standards for Cleaning and

Inspection?
Are there OPL's and/or SMP's to explain cleaning and
inspection standards?
Has this checklist been used by team to self evaluate
the step?

1-2

3-4 No

1-3

4-5 It doesn't exist

4

No

no

Yes
Exists but not detailed and
followed

exists and it is followed

Some

All
Yes

Autonomous Maintenance

STEP 0

AM
Autonomous
Maintenance

STEP 1
STEP 2
STEP 3
STEP 4
STEP 5

FI

TOPIC

(1)
Elimination of
causes of problems
and of inaccessible
areas

(3) Cleaning,
lubrication and
inspection
standards

PM
(4) Situation of
lubrication

L&CS
EEM/EPM
PD
ENV

No.

####

RATING STANDARDS

TOTAL

Self Evaluation

CHECKS

SCORE

REMARKS

Rating criteria
H

L (low )

M (medium)

3,01

Has the level achieved after application of the actions

identified in phase 2 been maintained in regards to:
(1) Elimination of causes of problems?
(2) Elimination of zones inaccessible for cleaning?

0-2

3-5

6-8

Problems arise but extra

It is not possible to maintain
corrective actions have been
the level achieved (80% of the
taken (85% of the objective
objective value).
value).

3,02

Are there still problems to be solved related to dirty

sources or inaccessible areas?

0-1

2-3

4-6

Drawbacks still exist and no

actions are planned.

3,03

What is the situation of cleaning of the

instrumentation/tools and of the auxiliary parts?

0-2

3-4

3,04

What is the situation as regards cleaning around the

machine?

0-2

3-4

3,05

Have the cleaning, inspection and lubrication points been

identified?

0-3

4-6

3,06

Is the AM standard calendar present at the machine?

3,07

Have CIL times, frequencies, descriptions been

continiously improved? Is there evidence of the method
used?

0-2

3-4

3,08

Is the AM calendar been followed?

0-3

4-7

3,09

Can lubrication points be identified with a mark and are

they mapped?

0-3

4-7

3,10

Are oil and grease for lubrication always traceable and

available?

0-2

3-4

3,11

Is the equipment necessary for lubrication present,

arranged tidily and orderly?

0-2

3-4

3,12

Are the oil level gauges and lubrication visual

management correctly indicated?

0-2

3-4

3,13

Has this checklist been used by team to self evaluate

the step?

(2) Maintenance of
initial cleaning

AM

QC

####

INTERNAL AUDITORS

Rating

S
CD

####

AREA

DATE

CHECK-LIST

STEP 6
STEP 7

CHECK-LIST STEP 3

PLANT

Defects have re-occurred but

action is being taken.

Only marginal presence of

dirt and/or foreign and/or
superfluous objects and/or
fused lights < 3.
Only marginal presence of dirt
5-7
and/or foreign objects and/or
superfluous objects.
The list exists but some
7-10 Not identified. There is no list. points have not yet been
identified.
5-7

Clearly evident dirt and/or

foreign and/or superfluous
objects and/or fused lights >
3.
Clearly evident dirt and/or
foreign objects and/or
superfluous objects.

H (high)
Maintenance assured by
activities scheduled and
completed. Process on
stream (at objective value,
90%).
No problems exist and the
actions scheduled are being
carried out.
There is no dirt and/or foreign
objects and/or superfluous
objects and/or fused lights.
There is no dirt and/or foreign
objects and/or superfluous
objects.
Identification of points has
been completed and these are
indicated in the list.

No

Yes
The sheet exists but
deployment has not been
formalized.

Exists and is formalized.

8-10 Followed 30%.

Followed 70%.

Followed 100%.

Points are not marked and not

8-10
mapped.
Oil and grease for lubrication
5-8 arranged in an untidy,
disorderly manner.
The equipment required is not
5-8
present.

There is a map but points are The mark exists and they are
not marked at the machine
numbered on the map.

5-7

5-8

No analysis and no method

Labels missing and no

lubrication visual
management.
no

Insufficient order and tidiness. Suitably tidied and arranged.

Exists but is not arranged in
an ideal manner.

The equipment is in order and

suitably arranged

There are labels but they are

not legible / incorrect.

Everything is perfectly visible

and understandable with a
good lubrication management
Yes

Autonomous Maintenance
AM calendar
MACHINE

GROUP

COMPONENT

PROG.

ACTIVITY DESCRIPTION

NSTD CYCLE

FREQUENCY

TIME
(min)

MACHINE
Working/Stop
ML = LAVORA
MF = FERMO

MACHINE "XX" AM CALENDAR

PLANNING

YEAR
MONTH 1

RIF. LAY
OUT
1

10

11

12

13

14

15

16

17

18

MONTH 2
19

20

21

22

23

24

25

26

27

28

29

30

31

10

11

12

13

14

15

16

17

18

MONTH 3
19

20

21

STEP 0
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
STEP 7
S
CD
FI
AM
PM

QC
L&CS

LEGEND

% ACTIVITY PLANNED
100%
90%

OPERATION COMPLETED

EEM/EPM
PD
ENV

80%
70%

EXTRA
CYCLE

EXECUTED DUE TO
BREAKDOWN

60%
50%
40%
30%

SCHEDULED OPERATION

20%

% ACTIVITY DONE

22

23

24

25

26

27

28

29

30

31

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

Autonomous Maintenance
SOP
DESCRIPTION SOP

SOP

DPI

STEP 4
STEP 6
STEP 7
S
CD
FI
AM
PM

QC
L&CS
EEM/EPM
PD
ENV

P A GE

PICTURES OP THE
OPERATION OF
PROCEDURE

cab 317

ES. 5
LINEA 1

STEP 2

STEP 5

P RODUCT

OPERATION DESCRIPTION

BASIC
DESCRIPTION OF
PROCEDURE

OP 30
(BMTM
8001)

NUMBER
SOP

STEP 1

OP

/
Rif.

STEP 0

STEP 3

A REA /LINE/M A CHINE

Autonomous Maintenance
SOP register
SOP: STANDARD OPERATING PROCEDURE (Diffusion)
STEP 0
STEP 1

SOP:

DATE

TEAM:

TRAINER

OPERATION:

USER

SIGNATURE

DATE

TRAINER

USER

STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
STEP 7
S
CD
FI
AM
PM

QC
L&CS
EEM/EPM
PD
ENV

Last release date:

#RIF!

WCM Support:

Pillar Leader:

SIGNATURE