Tools & Templates/Worksheets:

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TPM Autonomous Maintenance Audit Guide & Checklists

 

Description
 

Autonomous Maintenance (Jishu Hozen) is one of the most important building blocks in any Total Productive Maintenance (TPM) program. Autonomous Maintenance refers to TPM activities that involve operators in maintaining their own equipment, independent of the maintenance department. 

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Activities in an Autonomous Maintenance program include: daily inspections, lubrication, parts replacement, simple repairs, abnormality detection and precision checks.

 

The Autonomous Maintenance (AM) audit system assesses the progress made by production teams toward achieving the company's TPM goals. AM audits determine whether or not the teams are ready to move up to the next level of maturity with respect to the seven steps of the AM pillar. AM audits also expose weaknesses in the operators' knowledge, skills and equipment maintenance capability. The AM audit checklists therefore are an essential tool in the audit process. 

 

The AM audit step-by-step checklists are based on the TPM Excellence Framework. It consists of 6 checklists covering steps 1 to 6 of the AM pillar. The AM audit checklists are especially useful for companies who want to kick-start the AM implementation process and are not quite sure how to define the specific step-by-step AM practices, audit areas and evaluation points.

 

Developed by our JIPM-certified TPM consultant, the AM audit checklists are in Microsoft Office Excel format and can be easily tailored to suit your industry and machine or equipment type. 

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NOTE: This package includes:

1.  TPM Autonomous Maintenance PPT Guide (PowerPoint format)

2.  TPM Autonomous Maintenance Audit Step-by-Step Checklists (Excel format)

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Objectives

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1. Acquire a deep understanding of each step of the AM pillar for TPM excellence

2. Define the AM step-by-step audit areas and evaluation points

3. Conduct a systematic AM step-by-step audit for each equipment and identify areas for improvement

4. Establish a baseline position so you can measure your progress over time

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Contents

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1. Overview of the 7 Steps of AM

2. AM Audit Items & Evaluation Points

3. Anatomy of an AM Audit Checklist

4. Customising the AM Audit Checklists

5. How to Conduct an AM Audit

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Checklists included:

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1. AM Step 1 Audit Checklist: Audit Sheet for Initial Cleaning

2. AM Step 2 Audit Checklist: Audit Sheet for Sources of Dirt & Countermeasures for Difficult-to-access Locations

3. AM Step 3 Audit Checklist: Audit Sheet for Creating Cleaning & Lubrication Standards

4. AM Step 4 Audit Checklist: Audit Sheet for General Inspection

   • Step 4.1: General Inspection (Lubrication)​

   • Step 4.2: General Inspection (Hydraulic & Pneumatic)​

   • Step 4.3: General Inspection (Drive)​

   • Step 4.4: General Inspection (Electrical)​

   • Step 4.5: General Inspection (Lubrication)​

5. AM Step 5 Audit Checklist: Audit Sheet for Autonomous Inspection

6. AM Step 6 Audit Checklist: Audit Sheet for Order & Arrangement

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You may also be interested in the following training presentations and documents (sold separately):

1. Total Productive Maintenance (TPM)

2. Autonomous Maintenance (Jishu Hozen)

3. Focused Improvement (Kobetsu Kaizen)

4. Planned Maintenance (Keikaku Hozen)

5. Quality Maintenance (Hinshitsu Hozen)

6. Overall Equipment Effectiveness (OEE)

7. TPM Team Guide

8. TPM Self-Assessment Guide & Tool

9. TPM Autonomous Maintenance Audit Guide & Checklists

 

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