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Autonomous Maintenance (AM)

TQM International Pvt. Ltd.


52 Community Centre, 2nd Floor, East of Kailash, New Delhi-110 065
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4-AM.PPT/1

Why Autonomous Maintenance?

The equipment is filthy & stays that


way only

Oil & lubricants leaks are common


and lubricators are empty

Rotating parts & moving surfaces are


encrusted with grime & raw material

Wires & hoses are tangled and you


can't tell what is connected where

Equipment mechanisms are hidden by


big covers & you can't see inside

Materials, parts, tools and supplies


are strewn randomly & you can't tell
what is essential and what is not

Everyone is utterly convinced that


things have to be that way

Workplace suffer with many


defects & equipment breakdown

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Autonomous Maintenance

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4-AM.PPT/3

Autonomous Maintenance
The role of people is to
maintain machines
So that they work properly
Without breakdowns
Without defects
The principle in autonomous
maintenance is "I operate & I
Maintain the equipment"

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My machine
concept

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Autonomous Maintenance - Background


I Operate, You Maintain Wide gap in mind
set of operation & maintenance people

Poor/ no Analytical Approach

Inadequate Training

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Autonomous Maintenance - AIM


Develop Process & Equipment competent
Operators to enhance productivity We
operate We maintain We together WIN,
together LOOSE
Establishment of self management at
circle levels

To make all operators aware of loss, cost &


new techniques
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Autonomous Maintenance - PILLAR


Achievement Indexes

Variable cost
Fixed cost-Factory Overhead
Labour productivity
Added value productivity
Labour reduction ratio
Savings over previous corresponding period
Number of complaints-Quality & Short supplyNumber of accidents &hours lost.
Better space utilization

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4-AM.PPT/7

What is Autonomous Maintenance?

This part of maintenance is most important and performed


by operator themselves.

The operators take up the ownership of the equipment for


the maintenance.

The principle of I operate and I maintain is adopted.

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Goals of Autonomous Maintenance?


The goals of Autonomous maintenance is to keep the plant
operating efficiently so as to meet production targets without
any breakdowns. This is achieved by:
Preventive equipment deterioration through daily checks
Restore equipment to ideal state
Establishing basic conditions for upkeep of the equipment
By bringing flexibility in operators to operate and maintain
equipments
By focusing on reliability and maintainability

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Steps of Autonomous Maintenance


Step-7

Full self management


at circle levels

Step-6

Systemize Autonomous Maint.


through standardisation

Step-5

Developing process competent operator


for general inspection through training

Step-4

Developing equipment competent operator


through training for general inspection

Step-3

Establish cleaning, Inspection & lubrication standards to


keep equipment in peak optimal conditions and stop deterioration

Step-2

Eliminate source of contamination and inaccessible places to reduce


time for cleaning, checking and lubricate

Step-1

Perform Initial Cleaning to eliminate dirt,dust, grime and expose all


abnormalities
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Basic 7 steps of Autonomous Maintenance


Autonomous Maintenance activities are implemented
in steps and are only effective if progressed from one
step to next step is strictly controlled.

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First step Autonomous Maintenance?


Importance of Initial Cleaning: consists of removing all dust, dirt, grime, oil, grease, other
contaminants to equipment for exposing hidden defects.

Cleaning Inspection Sighting


abnormalities

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Breakdown occurs as we do not notice slight


problems or abnormal conditions
Slight problems include:
Dirt
Grime
Small amount of wear
Scratches
Play
Looseness
Leaks
Corrosion
Deformation
Vibration
Cracks
Excess heat
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Harmful affects on 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
Deterioration

Accumulated dust and grime make it difficult to find and


rectify cracks, excessive play, insufficient lubrication, and
other disorders, resulting in accelerated deterioration.

Speed
Losses

Dust and dirt increase wear and frictional resistance,


causing speed losses such as idling and underperformance.

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4-AM.PPT/13

Key Points for Cleaning


Cleaning is a form of inspection in TPM, so as to
expose hidden defects and abnormality in equipment.
Cleaning means

Regular practice as a part of daily work

Removal of layer of grime

Removal of dust & dirt in all attachment and


accessories

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Investigation of sources of contamination


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Key Points of Inspection


Cleaning as inspection means detecting abnormalities/ defects
in equipment so as to restore into working condition.
This means:
Searching visible defects i.e. looseness vibration,
overheating.
Searching worn out gullies, belts, block filters etc.
Searching easy method to lubricate operate and adjusts
Ensuring all meters operate correctly and clearly marked
with specific value.
Searching any leakages of product, steam, water, oil,
compressed air
Also searching hidden problems such as corrosion,
insulating material and blockages.
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What is Daily Checking?


Standards and one point lesson should be drawn up for daily
checks.
Check sheets are meaningful and in true sense daily inspection
should be carried accordingly.
Checkpoints for Nuts and Bolts
Slight defects

Are any nuts or bolts lose?


Are any nuts or bolts missing?

Bolt Lengths

Do all bolts protrude from nuts by 2-3 thread lengths?

Washers

Attachment of
Nuts and Bolts

Are bolts inserted from below, and are nuts visible from the outside?
Are devices such as limit switches secured by at least two bolts?
Are wing nuts on the right way around?

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Are
Are
Are
Are

flat washers used on long holes?


tapered washers used on angle bars and channels?
spring washers used where parts are subject to vibration?
identical washers used on identical parts?

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What is Daily Checking?


Lubrication checkpoints
Lubricant
Storage

Are lubricant storage always kept clean, tidy, and well-organized by thorough
application of the 5S principles?
Are lubricant containers always capped?
Are lubricant types clearly indicated and is proper stock control practiced?

Lubricant
Inlets

Are grease nipples, speed reducer lubricant ports, and other lubricant inlets
always kept clean?
Are lubricant inlets dust proofed?
Are lubricant inlets labeled with the correct type and quality of lubricant?

Oil-level
Gauges

Are oil-level gauges and lubricators always kept clean, and are oil levels easy
to see?
Is the correct oil level clearly marked?
Is equipment free of oil leaks, and are oil pipes and breathers unobstructed?

Automatic
Lubricating
Devices

Are automatic lubricating devices operating correctly and supplying the right
amount of lubricant?
Are any oil or grease pipes blocked, crushed or split?

Lubricant
condition

Are rotating parts, sliding parts, and transmissions (e.g. chains) always clean
and well-oiled?
Are the surroundings free of contamination by excess lubricant?

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What is Daily Checking?


Transmission System checkpoints
V-belts and
Pulleys

Roller
Chains

Shaft, Bearings,
and Couplings

Is there any overheating, vibration or abnormal noise due to excessive


play or poor lubrication?
Are any keys or set bolts loose or missing?
Are any couplings misaligned or wobbly?
Are any coupling seals worn? Are any bolts slack?

Gears

Are gears properly lubricated with the right amount of lubricant? Are the
surroundings clean?
Are any teeth worn, missing, damaged, or jammed?
Is there any unusual noise or vibration?

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Are any belts cracked, swollen, worn, or contaminated by oil or grease?


Are any bolts 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 of any pulley grooves shiny (indicating a worn belt or pulley)?
Are pulleys correctly aligned?
Are any chains stretched (indicating worn pins or bushings)?
Are any sprocket teeth worn, missing, or damaged?
Is lubrication between pins and bushings sufficient?
Are sprockets correctly aligned?

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What is Daily Checking?


Hydraulic units
Hydraulic
Units

Is the correct quantity of fluid in hydraulic reservoirs, and is the correct level
indicated?
Is fluid at the correct temperature? Are the maximum and minimum permissible
temperatures indicated?
Is fluid cloudy (indicating air entrainment)?
Are all fluid inlets and strainers clean?
Are any suction filters blocked?
Are any fluid reservoir breather filters blocked?
Are all fluid pumps operating normally without any unusual noise or vibration?
Are hydraulic pressures correct, and are operating ranges clearly displayed?

Heat
Exchangers

Is any fluid or water leaking from fluid coolers or pipes?


Are temperature differences between fluid and water inlets and outlets correct? Are
any tubes blocked?

Hydraulic
Equipment

Are there any fluid leaks?


Are hydraulic devices properly secured without any makeshift fastenings?
Are hydraulic devices operating correctly without speed losses or breathing?
Are hydraulic pressures correct, and are all pressure gauges working correctly (zero
points, deflection)?

Piping and
Wiring

Are
Are
Are
Are

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all pipes and hoses securely attahced?


there any fluid leaks? Are any hoses cracked or damaged?
all valves operating correctly? It is easy to see whether valves are open or shut?
any pipes, wires, or valves unnecessary?
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What is Daily Checking?


Pneumatic checkpoints
FRLs*

Are FRLs always kept clean? Is it easy to see inside them? Are they fitted the right
way around?
Is there sufficient oil, and are the drains clear?
Is the oil drip rate correct (approximately 1 drop for every 10 strokes)?
Are FRLs installed no more than 3 m from the pneumatic equipment?
Are pressures adjusted to the correct vale and are operating ranges clearly
indicated?

Pneumatic
Equipment

Piping and
Wiring

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Is any compressed air leaking from pneumatic cylinders or solenoid valves?


Are all pneumatic cylinders and solenoid valves firmly attached?
Are any makeshift fixings in use (wire, adhesive tape, etc.)?
Are any pistons dirty, worn, or damaged?
Are speed controllers installed the right way around?
Is there any abnormal noise or overheating of solenoid valves, and are any lead
wires chafed or trailing?

Are there any places in pneumatic pipes or hoses where fluid is liable to collect?
Are all popes and hoses clipped firmly into place?
Are there any compressed-air 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, wires, or valves unnecessary?
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What is Daily Checking?


Electrical checkpoints
Control
Panels

Are the interiors of distribution boards, switchboards, and control panels kept clean, tidy, and wellorganized by the application of the 5S principles? Have any extraneous 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 and clearly marked?
Are any instruments or display lamps broken? Are any bulbs faulty?
Are any switches broken? Do all switches work correctly?
Are control panel doors in good condition? Do they open and close easily?
Are there any unused holes? Are control panels waterproof and dustproof?

Electrical
equipment

Are all motors free of overheating, vibration, and unusual noise and smells?
Are all motor cooling fans and fins clean?
Are any attachment bolts loose? Are pedestals free of cracks and other damage?

Sensors

Switches

Are all manual switches clean, undamaged, and free of excessive play?
Are all switches installed in the correct position?
Are emergency stop switches installed in appropriate locations, and are they working correctly?

Piping and
Wiring

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Are
Are
Are
Are
Are
Are
Are

Are
Are
Are
Are

all limit switches clean and free of excessive play?


the interiors of all limit switches clean? Are any wires trailing? Are all covers in good condition?
any limit switches incorrectly installed?
any limit switch dogs worn, deformed, or the wrong shape?
all photoelectric switches and proximity switches clean and free of excessive play?
any sensors out of position? Are correct positions clearly indicated?
all lead wires un-safed, and is insulation intact at entry points?

any pipes, wires, or power leads loose or unsecured?


any ground wires damaged or disconnected?
any pipes corroded or damaged? Are there any bare wires or wires with damaged insulation?
any wires coiled on the floor or dangling overhead?

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What is Daily Checking?


Checkpoints for General-Purpose equipment
Pumps

Fans

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Are pumps and their stands free of unusual noise, vibration, and play?
Are pedestal bolts tight, corrosion-free, and undamaged?
Are stands and pedestals free of corrosion, cracking, and other damage?
Is any liquid leaking or spraying from gland packings?
Is any liquid leaking or spraying from pipes or valves?
Are any pipes or valves blocked?
Are all pressure gauges, vacuum gauges, flow meters, thermometers, and other measuring
instruments working properly and marked with the correct operating ranges?
Are starting current and operating current values correct? Are these clearly indicated?
Are all valves operating correctly? Is it easy to see whether valves are open or closed?
Are fans and their stands free of unusual noise, vibration, and play?
Are all pedestal bolts tight, corrosion-free, and other damage?
Are all stands and pedestals free of corrosion, cracking, and other damage?
Are any gland packings leaking air or gas?
Are any ducts or dampers leaking air or gas?
Are any ducts blocked or clogged?
Are all pressure gauges, vacuum gauges, flow meters, thermometers, and other measuring
instruments working properly and marked with the correct operating ranges?
Are starting current and operating current values correct? Are these clearly indicated?
Are all dampers operating correctly? Is easy to see whether dampers are opened or closed?

4-AM.PPT/22

Summary of CLIT
The idea is to restore the equipment
to basic conditions for normal
operation by:

Cleaning & inspecting: Keeping


dirt & grime off the equipment &
expo-sing defects & discovering
problems

Basics of cleaning & inspection

Lubrication: To prevent wear &


overheating of sliding & rotating
parts by providing proper
lubrication

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Tightening: Basic machine components like nuts & bolts. Missing or


loose bolts leading to excessive
vibrations & machine breakdowns
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Steps in Autonomous Maintenance


1. Preparation of employees.
2. Initial cleanup of machines.
3. Take counter measures
4. Fix tentative JH standards
5. General inspection
6. Autonomous inspection
7. Standardization and
8. Autonomous management.
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Train the Employees


Educate the employees about TPM, Its advantages, JH
(Jishu Hozen) advantages and Steps in JH. Educate
the employees about abnormalities in equipments.

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Initial cleanup of machines


Supervisor and technician should discuss and set a
date for implementing step
Arrange all items needed for cleaning
On the arranged date, employees should clean the
equipment completely with the help of
maintenance department.
Dust, stains, oils and grease has to be removed.
Following are the things that has to be taken care
while cleaning. They are Oil leakage, loose wires,
unfastened nuts and bolts and worn out parts.
Contd
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Initial cleanup of machines


After clean up problems are categorized and
suitably tagged. White tags is place where
problems can be solved by operators. Pink tag is
placed where the aid of maintenance department is
needed.
Contents of tag is transferred to a register.
Make note of area which were inaccessible.
Finally close the open parts of the machine and
run the machine.

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Counter Measures
Inaccessible regions had to be reached easily. E.g.
If there are many screw to open a fly wheel door,
hinge door can be used. Instead of opening a door
for inspecting the machine, acrylic sheets can be
used.
To prevent work out of machine parts necessary
action must be taken.
Machine parts should be modified to prevent
accumulation of dirt and dust.

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Tentative Standard
JH schedule has to be made and followed strictly.
Schedule should be made regarding cleaning,
inspection and lubrication and it also should include
details like when, what and how.

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General Inspection
The employees are trained in disciplines like
Pneumatics, electrical, hydraulics, lubricant and
coolant, drives, bolts, nuts and Safety.
This is necessary to improve the technical skills of
employees and to use inspection manuals
correctly.
After acquiring this new knowledge the employees
should share this with others.
By acquiring this new technical knowledge, the
operators are now well aware of machine parts.
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Abnormality detection and corrective action


Be able to spot abnormalities
Carry out daily checks reliably & judge correctly when
things are abnormal
Understand the structure & function (i.e. operation)
of the equipment
Use the five senses to catch abnormalities while the
equipment is running
Repair & restore
Improve machine operation to make it easier
Correct problems & restore equipment observing &
practicing simple repairs with maintenance people)
Set criteria
to draw up, apply & teach inspection criteria
Keep equipment running
by knowing how to operate equipment properly
Track down causes
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Autonomous Inspection
New methods of cleaning and lubricating are used.
Each employee prepares his own autonomous chart/ schedule
in consultation with supervisor.
Parts which have never given any problem or part which don't
need any inspection are removed from list permanently based
on experience.
Including good quality machine parts. This avoid defects due
to poor JH.
Inspection that is made in preventive maintenance is
included in JH.
The frequency of cleanup and inspection is reduced based on
experience.
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4-AM.PPT/32

Sample Cleaning, Checking and Lubrication


Standard
Cell -: Causticing Plant
Area
Classifica
tion
Cleaning

No.
1

Cleaning

Cleaning

Inspection

Vacuum
Gauge

Inspection

Bolts

Inspection

Cleaning

Lubricatio
n
Inspection

Vacuum pump(Causticizing Plant)

Cleaning

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Place or
Standards Method
Section
Cleaning of Free from Wiping
pump body dirt

10

Out let
water
header
Vacuum
Gauge

Equipment -: Mud Filer Area


Tools &
Time (In
Cycle
Handling
Secs)
300
D

Person in During
During
charge Operation Stoppage
OP

Free from Water


dirt
spray

120

OP

Free from Wiping


mist &
dirt
Within the Visual
indicated
value
range

60

OP

30

OP

1200

OP

1200

OP

Waste
cloth

600

OP

Grease
MP3
Visual

60

OP

600

OP

3600

OP

Tightened Tight all


bolts
V. Pump
Tightened Tight all
belts gaurd
bolts
Lubrication Free from
point
dirt,
grease &
lubricant
Shaft
Top Up
bearing
Repullper Cut in
& drive
Tyre , Oil
gear box.
seal
leakage
Drains
No
blockage

scrapping
mud

4-AM.PPT/33

Cleaning / Inspection Check-list


No.

Main response

Is there any dirt or dust in the oil inlet?

Do the oil level indicators show adequate levels?

Can the oil level indicators be clearly seen?

Are there crack in the oil tank?

Is the oil tank bottom dirty?

Is the oil in the tank dirty?

Is there any oil leakge from the tank?

Are oil levels adequate?

Is the correct type of oil being used?

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Restore

Replace

Lubricate

Clean

Point

O
O
O
O
O
O

O
O
4-AM.PPT/34

Cleanliness - Observation
Area / Object

Standard

No dirt ,dust, stain


No leakage / overflow -air,
oil, water, grease
No cobwebs
No bad odor
Not broken
Not slippery
..

Floor, Walls, Windows


Doors, Ceiling
Tables, Chairs
Equipments
Pipelines
Electric fittings
Carpets, Curtains
Pantry, Tea room, Toilet

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4-AM.PPT/35

5S Job Cycle Chart

Deptt.

Production: Assembly. Engine

Entered by

X&Y

Date:

1 Feb 2006

Standardize

Sustain

A (Continuous)

B (Daily M)

C (Daily E)

D (Weekly)

E (Monthly)

Red Tag Strategy (Repeated)

Place Indicators (Check or Make)

Item Indicators (Check or Make)

Amount Indicators (Check or Make)

Sweep around line

Sweep within line

Sweep around worktable

Sweep on and under worktable

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F (Occasionally)

Shine

5S job

Set in order

Red Tag Strategy (Occasional)

Sort

No.

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Standardization
Upto the previous stem only the machinery / equipment was
the concentration. However in this step the surroundings of
machinery are organized. Necessary items should be
organized, such that there is no searching and searching
time
is reduced.
Work environment is modified such that there is no difficulty
in getting any item.
Everybody should follow the work instructions strictly.
Necessary spares for equipments is planned and procured.

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Autonomous Management
OEE (Overall Equipment effectiveness) and other
TPM targets must be achieved by continuous
improvement through Kaizen.
PDCA (Plan-Do-Check-Act)
implemented for Kaizen.

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cycle

must

be

4-AM.PPT/38

The autonomous maintenance CAPD Cycle


Step 1
Perform Initial cleaning

Check equipment and expose


irregularities

Step 2
Control contamination sources
and improve inaccessible place

Act against contamination sources and


inaccessible places

Step 3
Establish cleaning and checking
standards

Plan and do checks based on


standards

Step 4
Perform general equipment
inspection

Repeat the CAPD cycle for each


category

Step 5
General process inspection

Repeat the CAPD cycle for each


category

Step 6
Systematize autonomous
maintenance

CAPDCAPD

Step 7
Practice
full self-management
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CAPDCAPD

P.D

4-AM.PPT/39

Sample manual on exposing


Seven steps of abnormality
Abnormality

Examples

1. Minor Flaws
Contamination
Damage
Play
Slackness
Abnormal
phenomena
Adhesion

Dust, dirt, powder, oil, grease, rust, paint


Cracking, crushing, deformation, chipping, bending
Shaking, failing out, tilling, eccentricity, wear, distortion, corrosion
Belts, chains
Unusual noise, overheating, vibration, strange smells, discoloration,
incorrect pressure or current
Blocking, hardening, accumulation of detins, pecking malfunction,

2. Unfulfilled Basic Conditions

Lubrication
Lubricant supply
Oil level gauges
Tightening

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Insufficient, dirty, unidentified, unsuitable, or leaking lubricant


Dirty, damaged or declared lubricant inlets, tautly lubricant pipes
Dirty, damaged, leaking; no indication of correct level
Nuts and bolts: slackens, missing, cross-threaded, too long, crushed,
corroded, washer unsuitable, wing nuts on backward

4-AM.PPT/40

Sample manual on exposing


Seven steps of abnormality
Abnormality

Examples

3. Inaccessible Places
Cleaning
Checking
Lubricating
Tightening
Operation
Adjustment

Machine construction, covers, layout, footholds, space


Covers, construction, layout, instrument position and orientation, operating-range
display
Position of lubricant inlet, construction, height, footholds, lubricant outlet, space
Covers, construction, layout, size, footholds, space
Machine layout: position of valves, switches, and levers; footholds
Position of pressure gauges, thermometers, flow meters, moisture gauges, vacuum
gauges, etc.

4. Contamination sources

Product
Raw materials
Lubricants
Gases
Liquids

Scrap
Other

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Leaks, spills, spurts, scatter, overflow


Leaks, spills, spurts, scatter, overflow
Leaking, spilt, and seeping lubricating oils, hydraulic fluid, fuel oil, etc.
Leaking compressed air, gases, steam, vapors, exhaust tumes,
Leaking, spilt and spurting cold water, hot water, half-finished products, cooling water,
waste water etc.
Flashes, cuttings, packaging materials, and nonconforming product
Contaminations brought in by people, fork-lift trucks, etc. and infiltrating through cracks
in buildings.

4-AM.PPT/41

Sample manual on exposing


Seven steps of abnormality
Abnormality

Examples

5. Quality Defect Sources

Foreign matter
Shock
Moisture
Grain size

Concentration
Viscosity

Inclusion, infiltration, and entrainment of rust, chips, wire scraps, insects, etc.
Dropping, jolting, collision, vibration
Too much, too little, infiltration, defective elimination
Abnormalities in screens, centrifugal separators, compressed-air separators,
etc.
Inadequate warming, heating, compounding mixing, evaporation, stirring etc.
Inadequate warming, heating, compounding mixing, evaporation, stirring etc.

6. Unnecessary and no-urgent items

Machinery
Piping equipment
Measuring instruments
Electrical equipment
Jigs and tools
Spare parts
Makeshift repairs

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Pumps, fans, compressors, columns, tanks, etc.


Pipes, hoses, ducts, valves, dampers, etc.
Temperatures, pressure gauges, vacuum gauges, ammeters, etc.
Wiring, piping, power leads, switches, plugs, etc.
General tools, cutting tools, jigs, molds, dies, frames, etc.
Standby equipment, spares, permanent stocks, auxiliary materials, etc.
Tape, string, wire, metal plates, etc.

4-AM.PPT/42

Sample manual on exposing


Seven steps of abnormality
Abnormality

Examples

7. Unsafe places
Floors
Steps
Lights
Rotating machinery
Lifting gear
Other

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Unevenness, ramps, projections, cracking, peeling, wear (steel deck


plates)
Too steep, irregular, peeling anti-slit covering, corrosion, missing
handrails
Dim, out or position, dirty or broken covers, not properly explosionproofed
Displaced, fallen of broken covers, no safety or emergency stop
devices
Wires, hooks, brakes, and other parts of cranes and hoists
Special substances, solvents, toxic gases, insulating materials, danger
sings, protective clothing, etc.

4-AM.PPT/43

Procedure for developing general


inspection training program
Establish general inspection categoris

(e.g. Nuts, bolts, lubrication system, pneumatics,


hydraulics, drives systems, electrics, etc.

Maintenance staff
Prepare

Prepare training materials


Maintenance staff

check sheets
Manual

Schedule training
Maintenance staff and
workplace supervisors

Cutaway models, wallcharts,


slides, etc.)

Train group leaders


Maintenance staff
Train

Prepare for relay teaching of group members


Group leaders;
workplace supervisors
Train group members

(General inspection of model equipment)

Group leaders
Conduct general inspection

(General inspection of all equipment)

Group members
A
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C
4-AM.PPT/44

Procedure for developing general


inspection training program
A

General
inspection

Hold group meetings, list abnormalities, plan


actions
Group members
Correct abnormalities

Abnormalities lists
(Deteriorated parts;
inaccessible areas)

Group members;
maintenance personnel
Establish provisional daily inspection standards
Group members
Assess inspection skills
General
inspection
Reinforcement

Group members
Perform self-audit and apply for official audit

Provisional standards
(On completion of each
category)
Skill assessment charts
(Practical tests)

Group members
Perform audit
Workplace supervisors;
maintenance staff
Treat problem areas indicated
Group members;
maintenance personnel

I0701 ISSUE 1

Move to next inspection category approximately


one category per month
4-AM.PPT/45

Action and visual control


Key Step 4 activities

Step 4: Conduct general


inspections

I0701 ISSUE 1

Learn the structure & functions of


your own equipment (training by
leader)

Test your understanding & then


actually inspect the equipment

Correct new problems you find

Establish thorough visual controls to


help control equipment conditions

4-AM.PPT/46

Effect of Autonomous Maintenance


FUGAI STATUS OF MUD FILTER AREA
70
60
50
40

16

15

15

18

30
20
10

Number of fuga i
ca rry ov er to next
month
Number of Fuga i
Elimina ted
5

31

33

10

6
15

0
Mar-07

Apr-07

May-07

11

Number of Fuga is
(identified+
ca rryov er)

Jun-07

Fugai means abnormality identified by Red or White


Tagging
I0701 ISSUE 1

4-AM.PPT/47

Examples
BEFORE
AFTER
I0701 ISSUE 1

Oil lubricant pipe


Placed outside as
No visual aid
Provided.

Visual aid
Provided to
ensure
continuous
flow of oil for
better lubrication
of journal bush.
4-AM.PPT/48

Examples
VISUAL AID
Working range Max
& Min. provided on
all gauges for
better Process
control

I0701 ISSUE 1

4-AM.PPT/49

Examples
All the open hot water lines were insulated to maintain a safe
working environment.

I0701 ISSUE 1

4-AM.PPT/50

Examples
BEFORE

Temporary pipes were


provided to prevent the
water splashing as the
vacuum in the Tray was
not sufficient enough
I0701 ISSUE 1

AFTER

The Vacuum valve was


changed & Vacuum intensity in
Tray increased; all the
temporary pipes removed.
4-AM.PPT/51

Lubrication identification

Lub oil-3

Lub oil-1
I0701 ISSUE 1

Lub oil-2
4-AM.PPT/52