TPM Autonomous Maintenance Audit Guide & Checklists

1. C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png TPM Autonomous Maintenance Audit Guide & Checklists This is a set of Autonomous Maintenance audit step-by-step checklists based on the TPM Excellence Framework. The audit tool is in Microsoft Office Excel format and can be tailored to suit your industry and machine or equipment. C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png © Operational Excellence Consulting. All rights reserved. © Operational Excellence Consulting. All rights reserved.

2. About the TPM AM Audit Checklists ▪ This is a set of Autonomous Maintenance audit step-by-step checklists 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. ▪ The AM audit checklists are in Microsoft Office Excel format and can be easily tailored to suit your industry and machine or equipment type. ▪ The audit tool is quite comprehensive and users may simplify the checklist items and/or the evaluation points to the level that your TPM teams and auditors are comfortable with. 2 © Operational Excellence Consulting. All rights reserved.

3. NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg Objectives By the end of the TPM Autonomous Maintenance evaluation, you will be able to: 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 3 © Operational Excellence Consulting. All rights reserved.

4. Contents 1. Overview of the 7 Steps of AM 2. AM Audit Items & Evaluation Points 3. Anatomy of an AM Audit Checklist 4. Customizing the AM Audit Checklist 5. How to Conduct an AM Audit 4 © Operational Excellence Consulting. All rights reserved.

5. 1 Overview of the 7 Steps of AM C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png © Operational Excellence Consulting. All rights reserved. 5

6. The 7 Steps of Autonomous Maintenance Steps of AM Main Objective 1. Clean and inspect 2. Eliminate problem sources and inaccessible areas To keep the state of the equipment from deteriorating 3. Draw up cleaning and lubricating standards 4. Conduct general inspections General inspection standards to complement the first 3 steps 5. Conduct autonomous inspections 6. Standardize through visual workplace management Focus on the entire work area 7. Implement autonomous equipment management Independent maintenance activities as part of business as usual 6 © Operational Excellence Consulting. All rights reserved.

7. 2 AM Audit Items & Evaluation Points C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png © Operational Excellence Consulting. All rights reserved. 7

8. AM Step 3 Audit (Partial Checklist) Step 3 Audit Sheet TPM Autonomous Maintenance Step 3 Subsection Section Audit date:__/__/__ Try again Pass 80 points or more General inspection __/100 points Department Audited by Audit Sheet for Creating Cleaning and Lubrication Standards Target equipment: Audit Point Evaluation Points Cleaner than when passed 5 Maintained as when passed 4 Below the level when passed 2 Passably Dirty Are clean conditions being maintained? Step 1 3 1 Maintenance and improvement of conditions when initial cleaning step was passed Being identified Cleaning is inspection Could do better Marking time Regressing Are Cleaning and Inspection being observed, are problems being identified? 5 4 3 2 1 Skills improved remarkably 5 Skills improved Greater detail No change in details Lesser detail Purpose: Are workers identifying problems with greater details, and is the next step after improving the skills of members understood? Definition of baseline conditions 4 3 2 1 Comments ___ / 15 points Audit Point Evaluation Points Maintainability is improved Could do better Oiling improved Not yet No improvement Step2 Are the improvements being made to lubrication and are these improvements leading to increased maintainability? Status of follow up on generating sources, difficult to access cleaning and lubrication locations, and countermeasures 5 4 3 2 1 Drafting of plan in progress 3 Meticulously planned Plan drafted Drafting of plan scheduled Not yet started Are plans being drafted again for those items which did not achieved adequate results from the countermeasures? 5 4 2 1 Almost completely unneeded 3 No blind spots Could do better Not yet Greatly needed Are further measures needed? (are any omissions in the countermeasures?) Purpose: 4 2 1 0 Improve reliability and maintainability Comments ___ / 14 points Audit Point Evaluation Points Where? Firmly decided Decided Passably Not decided Has the range of the division of oil responsibilities been decided? Who? 4 3 2 1 Firmly decided Decided Passably Not decided By what method? Are the methods and tools for cleaning and inspection decided? 4 3 2 1 When? Set appropriately Could do better Not yet Not decided Details of cleaning and inspection standards Are the period and time for cleaning and inspection set appropriately? How much? 4 3 2 1 Purpose: Clarified Could do better Not yet Not decided What? Is the object of cleaning and inspection clarified? Maintenance and control of cleaning and inspection 4 3 2 1 Observance of this procedure can be seen visually Procedure is observed, but not clearly Could do better Not recorded Is the cleaning status recorded on check-sheets, and is this consciously observed? 4 3 2 1 Comments ____ / 20 points 8 © Operational Excellence Consulting. All rights reserved.

9. AM Step 6 Audit (Partial Checklist) Step 6 Audit Sheet TPM Autonomous Maintenance Step 6 Subsection Section Audit date:__/__/__ Try again Pass 80 points or more General inspection __/100 points Department Audited by Order and Arrangement Audit Sheet Target equipment: Audit Point Evaluation Point Maintenance and Control Activities Improved since passing steps Below the level when passed Maintained as when passed Passably Are the conditions at the time of passing previous steps being maintained? 3 2 1 0 All have been improved or are scheduled to be improved 3 Problems with maintaining autonomous maintenance Improved for the most part Low rate of implementation Have improvements and measures been taken for items cited at previous diagnoses? 2 1 0 (Status of follow-up on Steps1-5) Steadily implemented and thoroughly established Problems with mainaining autonomous maintenance Reevaluation could be better Inadequate implementation Is autonomous maintenance being steadily implemented, and are standards being reevaluated as needed? 4 3 2 0 Establish and maintained in good condition Standards are being observed for the most part Could do better Still inadequate Has the maintenance (cleaning, oiling and retightening) of basic conditions been established? 3 2 1 0 Extremely good Passably Could do better Still inadequate Do the 5S of workplace improve? 3 2 1 0 Comments ____ / 16 points Audit Point Evaluation Point Order and Arrangement "Equipment" Inspection work is well understood Being implemented Could do better Inadequately Are check-sheets being used, and is inspection work being carried out steadily? 3 2 1 0 Items are understood but not incorporated Leads to good results Incorporated Items are not understood Are quality control items incorporated in the inspection items, and does this lead to a reduction in defects? 3 2 1 0 (Make firm decisions and steadily observe them) Handled reliably Passably Could do better Inadequately Are equipment problems handled speedily and reliably? 3 2 1 0 Thoroughly implemented, and anyone can determine problems 4 Can be visually determined for the most part Cannot be understood without explanation Not making progress Is visual management thoroughly implemented, and have means been devised so that anyone can determine visually whether there is a problem? Inspection of equipment accuracy 3 2 0 Making good progress Making partial progress Ubder consideration Not making progress Are the number of inspection items being reduced, and is the introduction of predictive maintenance making progress? 3 2 1 0 Implemented in accordance with standards for the most part 2 There are standards and they are firmly established Could do better Still inadequate Are standards set for routine checking of detection and control equipment, and are their functions being verified? 3 1 0 Comments ____ / 19 points 9 © Operational Excellence Consulting. All rights reserved.

10. 3 Anatomy of an AM Audit Checklist C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png © Operational Excellence Consulting. All rights reserved. 10

11. Anatomy of AM Audit Checklist Step 3 Audit Sheet TPM Autonomous Maintenance Step 3 Subsection Section Audit date:__/__/__ Try again Pass 80 points or more General inspection __/100 points Department Audited by Audit Sheet for Creating Cleaning and Lubrication Standards Target equipment: Audit Point Evaluation Points Passably Are clean conditions being maintained? Cleaner than when passed Maintained as when passed 4 Cleaning is inspection Below the level when passed 2 Marking time Dirty Step 1 Maintenance and improvement of conditions when initial cleaning step was passed 5 3 1 Are Cleaning and Inspection being observed, are problems being identified? Being identified Could do better Regressing 5 4 3 2 1 Are workers identifying problems with greater details, and is the next step after improving the skills of members understood? Skills improved remarkably Skills improved Greater detail No change in details Lesser detail Purpose: Definition of baseline conditions 5 4 3 2 1 Comments ___ / 15 points Evaluation Points Audit Items Area for comments 11 © Operational Excellence Consulting. All rights reserved.

12. 4 Customizing the AM Audit Checklist C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png © Operational Excellence Consulting. All rights reserved. 12

13. Customizing the Checklist ▪ The set of audit checklists provided are designed for a manufacturing environment and are quite comprehensive. ▪ To make the checklists more relevant to your industry or company, the audit items and evaluation points for each step of AM should be tailored to suit your specific industry or machine/equipment. ▪ If your organization has just started on the TPM journey, you may simplify the checklists (so as not to scare the TPM teams and auditors) initially and then review later if additional audit items should be added or refined as you gain more practical experience from the audit activities. 13 © Operational Excellence Consulting. All rights reserved.

14. Customizing the Audit Items ▪ The AM audit checklists are not meant to be prescriptive and you may tailor them to a level that the auditors and the TPM teams are comfortable using them. ▪ As an option, you may adopt the ECRS approach to customize the checklists: – Eliminate the audit items that are not relevant to your equipment – Combine two or more audit items and group them into just one item – Reduce the number of audit items – Simplify the audit items ▪ Do note that you may need to redistribute the evaluation points to maintain the 100-point score for the AM step. Alternatively, convert the score to percentage instead. 14 © Operational Excellence Consulting. All rights reserved.

15. 5 How to Conduct an AM Audit C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png © Operational Excellence Consulting. All rights reserved. 15

16. How to Conduct an AM Audit 1. The audit checklists consist of two main columns: a. Audit Items/Points (in yellow) b. Evaluation Points (in green). 2. Each audit item/point is to be evaluated over its corresponding evaluation scale. Use the point descriptors to help you decide which score best represents the current audit status. 3. Write down any observed strengths, weaknesses or evidences under the ‘Comments’ area. The information should be helpful for the auditee teams to develop improvements plans. 4. Add up all the points for the step audit and write the total score on the top right of the audit sheet. The maximum possible score is 100 points. 16 © Operational Excellence Consulting. All rights reserved.

17. Auditing as a Team 1. Instead of a single auditor, the AM step audit can also be done by a team of auditors. The team can be formed by auditors from other production areas and may include leaders, supervisors or managers. 2. A copy of the step audit sheet should be given to each member of the audit team. 3. The audit team will need to convene one or more planning session(s) to decide on the procedures and schedule for carrying out the audit activity. 4. They may need to review the audit checklist to identify the basic information that needs to be gathered to facilitate the audit process. 17 © Operational Excellence Consulting. All rights reserved.

18. Writing the Strengths & Areas for Improvement 1. For each group of audit items, write down the strengths and areas for improvement under the ‘Comments’ area. 2. The strengths identified should relate to the top scoring 1-2 evaluation boxes. 3. Similarly, the areas for improvement identified should be related to the lowest 1-2 audit items. 18 © Operational Excellence Consulting. All rights reserved.

19. C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png About Operational Excellence Consulting ▪ Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. ▪ One of our unique strengths is going beyond a tools-focused approach to seamlessly integrate people, processes, technology and continuous improvement initiatives to suit the specific needs and situations of our clients. ▪ We provide corporate learning programs and management advisory services to assist our clients to achieve breakthrough in business performance and effectiveness. Our aim is to support our clients in designing, managing and executing lasting beneficial change. 19 © Operational Excellence Consulting. All rights reserved.

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