STEP 3
TOTAL PRODUCTIVE
MAINTENANCE STEP
3 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 3
The purpose of this audit is to ensure the Step 2 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 3 AM – CLEANING, INSPECTION AND LUBRICATION STANDARDS
REQUIREMENT
Details of cleaning and inspection standards:
- Visuals in place, eg: flow direction marks, bolt match
mark, pressure gauge range marking, colour coded
pipes.
SCORE
______
-
Has the range of the cleaning and inspection
responsibilities been decided?
______
-
Are
the
methods
and
for cleaning and inspection decided?
tools
______
-
Is the period and time for cleaning and inspection set
appropriately?
______
-
Cleaning standards are specific to this machine and is
the object of cleaning and inspection clarified?
______
-
Is the cleaning status recorded on check sheets and is
this conscientiously observed?
______
-
Is inspection using senses evident based on set
standards (kpa, Nm, mm)
______
-
Training and clarity among members
______
Details of oiling standard:
- Has the range of the Division of oil responsibilities
been decided?
-
RESPONSIBLE
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
______
Are
the
oiling
methods
and
tools
decided and in a fixed location and near the machine
(5S of the storage location)?
______
-
Are the period and time set appropriately?
______
-
Are the type, quality and quantity of oil decided?
______
TPM STEP 3 AUDIT
1
-
Is the objective of oiling clarified?
______
-
Is the oil easy to see and is the oiler functioning
normally?
______
-
Is the oiling inlet dirty? Also, are means being devised
to prevent it from being dirtied?
______
-
Is a check sheet used to keep records and is this done
conscientiously?
______
-
Is the lubrication standards set? (How much, who,
why, How)
______
-
Current type of lubrication analysed?
______
Status of autonomous maintenance activities:
- Are the overall schedule and the current month
schedule clearly defined?
-
-
-
Autonomous Maintenance
Pillar Head
______
Is a record documenting losses being kept so that
problems can be reduced?
______
Are the results of countermeasures made apparent
through Kaizens or OPL’s?
______
Are standards created in meetings and is the
importance of observing these standards thoroughly
communicated?
______
Evidence requirements must be sought for each point to ensure the documentation is in use and activities.
STEP 1 & 2 AM – FOLLOW UP ON SOURCES OF CONTAMINATION AND HARD TO AREAS
REQUIREMENT
Initial cleaning:
- Are clean conditions being maintained?
-
Is "Cleaning is Inspection" being observed and are
problems being identified?
Are team members identifying problems with greater
detail and is the next step after improving the skill of
members understood?
Sources and type of contamination:
- Are improvements being made to oiling and are these
improvements leading to increased maintainability?
SCORE
______
RESPONSIBLE
Autonomous Maintenance
Pillar Head
______
-
-
______
Autonomous Maintenance
Pillar Head
______
Are plans being drafted again for those items which
did not achieve adequate results from the
TPM STEP 3 AUDIT
2
countermeasures?
______
-
Are further measures needed? (Are any omissions in
the countermeasures?)
Knowledge Test 1 Pillar Heads or Shop Floor:
Where the most frequent losses and what are they?
Operator to use the visual board and refer to the loss map
and OEE metrics and explain them
Knowledge Test 1 Pillar Heads:
Explain four of the 7QC tools in detail. What they are and
where they are used and provide examples that are well
explained of where the operators have used the tools to
solve problems.
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.
Preparation of tools:
- Cleaning tools are in place and are adequate to clean
in accordance with the cleaning instruction. Operator
to explain the use of the tools using the OPL if
necessary
Contamination Sources:
- Operator to discuss the types of contamination in
detail, where they occur, what they are and apply
the 5why technique when requested.
Autonomous Maintenance
Pillar Head/Shop Floor
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
FOCUSSED IMPROVEMENT STEP 1-7
FOCUSSED IMPROVEMENT AUDIT
REQUIREMENT
Kaizen A3 Summary Sheet:
- Kaizens for cleaning, inspection and lubrication
improvements are provided
-
SCORE
______
Kaizens for loss reduction are clearly labelled with
impact in line with the KPI’s established and required.
______
Kaizens for cleaning improvement focussing on the
elimination of contamination sources are provided
and the impact detailed accordingly.
______
-
Kaizens for standard identification?
______
-
Kaizens have been closed off showing some results
to date of improvement
______
-
RESPONSIBLE
Focussed Improvement
Pillar Head
TPM STEP 3 AUDIT
3
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.
Training and Development Matrix: Who has been trained,
what is their level of competence towards TPM? The matrix
should follow a competency check.
Focussed Improvement
Pillar Head
Focussed Improvement
Pillar Head
Education and Training
Pillar Head
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 pillars.
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
TPM STEP 3 AUDIT
4
STEERING COMMITTEE TEAM:
TPM STEP 3 AUDIT
5