STEP 1
STEP1
TOTAL PRODUCTIVE
MAINTENACE STEP 1
AUDIT
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
One-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.
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.
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.
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.
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
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.
SCORE
RESPONSIBLE
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
Focussed Improvement
and Autonomous
Maintenance Team.
Ownership should reside
with production once
maintenance has defined
the cleaning specifications.
Autonomous Maintenance
Pillar Head
Steering Committee
TPM STEP 1 AUDIT
1
Evidence requirements must be sought for each point to ensure the documentation is in use and activities.
STEP 1 AM PRACTICE EVIDENCE
REQUIREMENT
Cleaning Exercise: Cleaning exercise is being adhered to in
line with the cleaning instruction for the area/equipment.
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
Knowledge Test 1 Pillar Heads: Explain the measure for TPM
Implementation. Overall equipment effectiveness
SCORE
RESPONSIBLE
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head/Shop Floor
Autonomous Maintenance
Pillar Head
Explain why the initial cleaning exercise is performed daily?
As a mechanism to inspect and ensure equipment
functioning.
Visual Advice: Area standards provided with photos of what
the area should look like complete with labelling, markings
etc.
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.
Preparation of tools: Organisation evident of tools and
production items in use as per agreed standardised defined
through the sorting process
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
Autonomous Maintenance
Pillar Head
Red Tags – AM Pillar Head
and White Tags – FI Pillar
Head
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
FOCUSSED IMPROVEMENT STEP 1-7
FOCUSSED IMPROVEMENT AUDIT
REQUIREMENT
Kaizen 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
Stepped FI plan with a list of all projects: A detailed list of
projects, expected completion date, responsible parties
Visual Board Update: All projects presented onto the visual
board and tracked as per the weekly meetings. Team
structures.
Evidence of 7 QC tools: Ishikawa, Cause and Effect Matrix,
FMEA, Control Charts, Run Charts for improvement tracking
Training and Development Matrix: Who has been trained,
SCORE
RESPONSIBLE
Focussed Improvement
Pillar Head
Focussed Improvement
Pillar Head
Focussed Improvement
Pillar Head
Focussed Improvement
Pillar Head
Education and Training
TPM STEP 1 AUDIT
2
what is their level of competence towards TPM? The matrix
Pillar Head
should follow a competency check.
STEERING COMMITTEE REQUIREMENTS
REQUIREMENT
SCORE
RESPONSIBLE
Declaration: A company communication stipulating the
Focussed Improvement
objectives and commitment to TPM.
Pillar Head
FI and AM Team Structures: Officiated organograms outlining
Focussed Improvement
team structures for the AM and FI piilars.
Pillar Head
KPI’s: All projects and training are required to have KPI’s
Focussed Improvement
linked to a master KPI allocation. These are then cross
Pillar Head
referenced with Kaizen events and Am activities.
TOTAL SCORE
:
PERCENTAGE
:
RESULT
:
COMMENTS
AUDITORS:
PILLAR HEADS
STEERING COMMITTEE TEAM:
TPM STEP 1 AUDIT
3