F-TAG (Tagging)

• F-Tag should be attached to the following malfunctions:

Wear, Play, Slackness
Leakage
Dust, Dirt
Corrosion
Adherence of raw materials,
Deformation, Surface damage, Cracking
Overheating, Vibration, Noise …

Examples of “Fuguai” – Potential problems

Categories of Fuguai

Examples

Examples of check point

Minor defects

Dirtiness

Scratches

Play

Looseness

Abnormality

Adhesion

Dust, dirt, powders, oil, rust and paint

Cracking, collapsed, deformed, chipping, bends

Shake, slip off tilting, eccentricity, wear, distortion, corrosion.

Bolt, nut, gauge, cover, belt, chain;

Looseness, Omission, Incorrect tightening, Excessively long bolt, Battered threads,

Corrosion, Incorrect washer, Bolt direction, Double nut put in reverse.

Abnormal sound, heat, vibration, offensive odor, discoloration, pressure

Clogging, sticking, deposition, peeling off

Lubrication

Leaking

Incorrect conditions

Incorrect indicators

Oil depletion, dirty oil, oil type (not known, inadequate), leak

Dirty oil support port, clogging, damage, deformation, collapsed pipe,

storage condition, inadequate oiling equipment

Dirtiness, damage, leak, wrong level indication

Source of contamination

Products, Raw Materials

Hydraulic oil, Liquid

Gasses

Machining & Processing

Other

Leak, spilling, blowing off, scattering, overflow

Leak, spilling or permeation of fluid

Leak, spilling air, gasses, steam, vapor, exhaust water

Burrs, chips, packing, sputters, sparks, smokes, adhesive, paints

Dropped parts

Hard to reach areas

Cleaning / Inspection

Lubrication

Operation

> Equipment structure, cover, layout, foothold, space, installing height high or low, indicators inadequate

Quality defects

Foreign maters

Manufacturing condition

Leaking, overflow

Humidity, vibration, collision, temperature

Unnecessary things

Equipment components,

Products, Tools, Jigs, Spare parts, Pipes

Mess, disorder,

Safety concerns

Incorrect conditions

Incorrect indicators

Floor, Steps, Stairs; unevenness, cracks, peeling off, wear

Lighting; dark

Safety devices; broken, worn stoppers, wear

F-Tag Log

F-Tags – Abnormality Tally Sheet

Category of Potential problems Location of F-Tags attached		Dust, Dirt, Leak, Splash, Rust, Scratches	Chattering, Loosening, Missing	Wear, Broken, Bent	Chipping, Missing, Holes, Unevenness, Inclined	Abnormal noise, Excessive heat, Vibration, Odor, Discoloration, Abnormal movement	Hard to clean, Lubricate and Inspect	Other
External surface of equipment	Body, Covers, Piping, Wiring, Valves, Pneumatic set, etc.
Door / inside of covers	Safety cover, Operating/ control panel, Inspection hole, etc.
Associated equipment	Hydraulic unit, Lubrication tank.
Peripheral equipment	Measurement , jigs, Tools
Transportation system	Chute, Conveyors, Turntable, etc./
Production floor around the equipment	Floor, Pit under the floor, wall, etc.
Others

1^st Step – “Initial-Clean” Diagnosis Checklist

Equipment ID

	Items	Check the following	Evaluation	Comments
1	Main body	How well are the dust, oil and grease, and chips removed? How about the condition of work and tools? (Such area as tools and Jigs surfaces, chuck, sliding portion, chute, frame, bed, piping and wiring, etc.)	1 – 2 – 3 – 4 – 5
2		Free from loosening, chattering, vibration, excessive wear and heat build-up (in such areas as bolts, nuts jigs, Rotating portions, Sliding portions and Chute, etc.)	1 – 2 – 3 – 4 – 5
3	Sub-equipment	Free from dust, oil and grease or any other foreign materials. (Cylinders, Solenoids, Air line combination units, Motors, Limit switches, Belts, Proximity switches, photoelectric Switches, Control panels etc.	1 – 2 – 3 – 4 – 5
4		Free from loosening, chattering, vibration, excessive wear and heat built up, and roaring. (Motors, Solenoid valves, Limit switches, Installation board, relays, Wiring, Bolts and Nuts, etc.)	1 – 2 – 3 – 4 – 5
5	Lubrication	Free from dust, dirt and oil stain. (Lubricator, Oil cups, Measuring instruments, Cap of oil filler, Oil supply piping, etc.)	1 – 2 – 3 – 4 – 5
6		Proper oil level and oil flow rate, free from loosening, chattering, and vibration. (Check for contaminated oil, oil deterioration, Loose piping joints, Valve, Speed control, Oil temperature, etc.)	1 – 2 – 3 – 4 – 5
7	Around the equipment & machine	Cleaning condition of tools, measuring instruments and gauges, and spare parts. Are the cover, name plate and label in good conditions? *Are the unnecessary parts, products and replacement parts in good order?	1 – 2 – 3 – 4 – 5
8		Are the accepted products properly segregated from rejected products? Are the proper passages provided? *No flying dust from adjacent equipment.	1 – 2 – 3 – 4 – 5
9	Countermeasures for the source of contamination & improving hard-to-access area	Has any list showing the sources of dust, dirt, oil leakage and the areas difficult to keep clean been prepared? And Is there any Action Plan for cleaning?	1 – 2 – 3 – 4 – 5
10		Have the cover and housekeeping utensils been improved? Is there any point you should check while performing the housekeeping? *Has the responsibility for cleaning the areas been properly assigned to each operator?	1 – 2 – 3 – 4 – 5
		Summarize up Floor Diagnosis	Σ
11	Group Activity	Is Annual Target clear? And visualize relationship to Company Target clearly?	1 – 2 – 3 – 4 – 5
12	(TPM Activity Board)	Are OEE, # of Breakdown, Quality Defects etc. tracking periodically?	1 – 2 – 3 – 4 – 5
13		Are F-Tags organized visually, effectively?	1 – 2 – 3 – 4 – 5
14		Are One-Point Lessons made effectively? And Does Transmitted Training implement by One-Point Lessons.?	1 – 2 – 3 – 4 – 5
15		Is Autonomous Maintenance allocated to all team members clearly? Is Specific responsibility of members clear?	1 – 2 – 3 – 4 – 5
		Summarize up Group Activity	Σ
		*Note	Σ	(PASS) (FAIL)

* NOTE; PASS MARK is more than 80% (Σ(Floor-diagnosis(1-10) Evaluation Point + Σ(Group Activity(11-15) Evaluation Point))

2^nd Step – “Countermeasure for source of contamination & hard-to-access area” Diagnosis Checklist

Equipment ID

	Items	Check the following	Evaluation	Comment
1	Review 1^st Step	Is cleaning level of 1^st step (Initial clean-up) good, and is it maintained?	1-2-3-4-5-6-7-8-9-10
2	Countermeasure for Equipment main body	Are the cause sources such as dirt, dust, oil leakage, air leakage summarized into a list, and are countermeasures for the causes taken?	1 – 2 – 3 – 4 – 5
3		Are the hard-to-access areas summarized into a list, and are the state of contrivance and improve good? (Are cleaning tool covers removed, put in order and arrangement.)	1 – 2 – 3 – 4 – 5
4	Countermeasure for Sub-equipment	Are the causes of trouble such as dirt, dust, oil leakage, air leakage summarized into a list, and are countermeasures for the causes taken?	1 – 2 – 3 – 4 – 5
5		Are the hard-to-access areas summarized into a list, and are the state of contrivance and improve good? (Are cleaning tool covers removed, put in order and arrangement.)	1 – 2 – 3 – 4 – 5
6	Around the equipment & machine	Are the source of contamination such as dirt, dust, oil leakage, air leakage put F-TAG, and summarized into a list, and are temporary action taken?	1 – 2 – 3 – 4 – 5
7		Are the hard-to-clean areas, put F-TAG and summarized into a list, and are improved? (Are cleaning tool covers removed, put in order and arrangement.)	1 – 2 – 3 – 4 – 5
8	Visual Control	Is Visual Control conducted effectively such as the follows; Gages normal operating range, Critical Nuts & Bolts match mark. Hoses & Pipes color coded by product and flow direction Motors & Drives marked with rotation arrows? Lubrication type identified? And MAX-MIN marked?	1-2-3-4-5-6-7-8-9-10
		Summarize up Floor Diagnosis	Σ
9	Group Activity (TPM Activity Board)	TPM Activity Board being used? * Are OEE, # of Breakdown, Quality Defects etc. tracking periodically * Are F-Tags organized visually, effectively? * Are One-Point Lessons made effectively? And Does Transmitted Training implement by One-Point Lessons.?	1-2-3-4-5-6-7-8-9-10
10		Is there any plan to maintain and improve Equipment Basic Conditions? * Action plan for Improvement of 2^nd Step * How to allocate Autonomous Maintenance Activity to all team members (Roll-Assignment Table, Map)	1 – 2 – 3 – 4 – 5
11		Is there any good improvement example of action for source of contamination?	1 – 2 – 3 – 4 – 5
12		Is there any good improvement example of action for Hard-to Access area, Visual Control?	1 – 2 – 3 – 4 – 5
		Summarize up Group Activity	Σ
		*NOTE	Σ	(PASS) (FAIL)

NOTE; PASS MARK is more than 80% (Σ(Floor-diagnosis(1-8) Evaluation Point + Σ(Group Activity(9-12) Evaluation Point)).

3^rd Step – “Preparation of tentative autonomous maintenance standards” Diagnosis Checklist

Equipment ID

	Items	Check the following	Evaluation	Comment
1	Review 1^st Step & 2^nd Step	Are 1^st Step (Initial clean-up) conditions and 2^nd Step improved level maintained?	1-5-10-15-20
2	Cleaning & Inspection Standard	(Cleaning & Inspection standard) Is the standard made out according to the equipment and location? Are cleaning & Inspection section, location and assignment specified? Are methods and tools specified? Are Cleaning & Inspection Time and Frequency properly visualized and implemented? Are the contents clear and understandable by everybody?	1-2-3-4-5-6-7-8-9-10
3		(Tightening) Are bolts and nuts loose? Are there any bolts and nuts missing?	1 – 2 – 3 – 4 -5
4	Lubrication Standard	(Lubrication standard) Are kind of lubrication, amount, cycle, method and assignment specified? Are proper labels applied to lubrication points? Is the oil ready for lubrication all the time? Is the oil storage location tidy?	1-2-3-4-5-6-7-8-9-10
5	Awareness of one’s own role in making the standard	Are the improvement and new ideas for Easy-to do and Visual Control implemented actively?	1 – 2 – 3 – 4 -5
		Summarize up Floor Diagnosis	Σ
6	Group Activity (TPM Activity Board)	TPM Activity Board being used? * Are OEE, # of Breakdown, Quality Defects etc. tracking periodically * Are F-Tags organized visually, effectively? * Are One-Point Lessons made effectively? And Does Transmitted Training implement by One-Point Lessons.?	1 – 2 – 3 – 4 -5
7		Is Activity observed accordance with Autonomous Maintenance Standard?	1 – 2 – 3 – 4 -5
8		Is Autonomous Maintenance Standard up to date by Team?	1 – 2 – 3 – 4 -5
9		Is Equipment Breakdown Log tracked by team? And Is Breakdown Analysis implemented?	1 – 2 – 3 – 4 -5
10		Is Skill-Training for operators implemented periodically?	1 – 2 – 3 – 4 -5
		Summarize up Group Activity	Σ
		*NOTE	Σ	(PASS) (FAIL)

NOTE; PASS MARK is more than 80% (Σ(Floor-diagnosis(1-5) Evaluation Point + Σ(Group Activity(6-10) Evaluation Point))

Application Form for Autonomous Maintenance Step Diagnosis

STEP

4-1

4-2

4-3

4-4

4-5

Requested Step Diagnosis Date & Time

Manager

Supervisor

Team Leader

Team Member	Responsibility	Step Diagnosis Applied Machine ID;
		1)
		2)
		3)
		4)
		5)
		6)
		7)
		8)

Activity Log

When (Who) What How

SOCS & HTA Matrix

Equipment ID

Category	Items	#	#	#	#	#	#	#
	Where is it seen?
Countermeasure for source of contamination	Describe the state of dirt.
	What make dirty.
	When is it? (During continuous processing, At start up…)
	How is it? (Scatter?, Leak?…)
	Why is it?
Countermeasure for hard-to-access area	What is it difficult? (Cleaning, Inspection, Lubrication)
	Why is it difficult? High-Low Behind *Hard-to-remove…
Hints of improvement	Eliminate; Eliminate the source of contamination its self, hard-to-access area its self.
	Combine; Combine ” where” (Gather, Receive…)
	Replace; Replace “where” (Change “where”)
	Simplify; (Sucking, Washing)
Log by One-point Lesson sheet	ID

Routine Cleaning, Inspection & Lubrication Standard

Dept. / Line

Machine ID

Diagram

No.

Item

Criterion

method

Tools

Time

Freq.

Person

(Min)

Resp.

Routine Cleaning Inspection and Lubrication Standard

Note: (Freq.) S =Shift, D =Day, W =Week, if necessary, 2W=Two week, M =Month

Routine Cleaning Inspection & Lubrication Standard

Dept. / Line

Machine ID

Diagram

No.

Item

Criterion

Method

Tools

Time

Freq.

Person

(Min)

Resp.

Cleaning

Hydraulic unit

Be clean

Wipe

Rag

Main Motor

Be clean

Wipe

Rag

Inspection

Pressure gauge

£ 5 kgf

Visual

0.5

Lubrication

Note: (Freq.) S =Shift, D =Day, W =Week, if necessary, 2W=Two week, M =Month

TPM Activity Board Requirements (Activity Board for First-line Small Group)

1. Policy & Implementation plan

1-1 Policy & Target

Company / Factory policy & target / Department / Team policy & target (Annual, quarterly)

1-2 Action plan; TPM Master plan (Plant-wide and long term) / Team implementation plan (Annual plan and Quarterly)

2. Indicators (Measurables)

2.1 Tracking data (Monthly or Weekly)

Productivity (Output per hour person)
Quality (# of scrap and type of scrap)
Cost (Overall Equipment Efficiency – Bottle neck machine)
Delivery & Availability – Zero Breakdown calendar

(On-time delivery ratio, # of unscheduled breakdown, downtime, change over time

Safety (Lost time injury)

2.2 Data collection (Daily or Every shift)

# of breakdown
# of scrap and type of scrap, rework
Change over time , Time and Operation Analysis Chart
# of minor stoppage

3. Action taken

One Point lesson (Basic knowledge / Improvement case / Troubleshooting)
Tag (Blue / Red ) & Tag-list (Fuguai list)
5-why analysis / P-M Analysis
Autonomous Maintenance standards

4. Review of action taken

# of One-point lesson
# of Tag (Blue / Red)
Step Diagnosis comment, score & sticker

No.	Date	Priority	Type of F-Tag	Description of Problem	Result if left not repaired	Why did it become so? (What is the cause?)	Action	Person Responsible	Planned Date	Date Completed
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Autonomous Maintenance 1st step – 3rd step

F-TAG (Tagging)

Examples of “Fuguai” – Potential problems

F-Tag Log

F-Tags – Abnormality Tally Sheet

1st Step – “Initial-Clean” Diagnosis Checklist

2nd Step – “Countermeasure for source of contamination & hard-to-access area” Diagnosis Checklist

3rd Step – “Preparation of tentative autonomous maintenance standards” Diagnosis Checklist

Application Form for Autonomous Maintenance Step Diagnosis

SOCS & HTA Matrix

Routine Cleaning, Inspection & Lubrication Standard

TPM Activity Board Requirements (Activity Board for First-line Small Group)

1. Policy & Implementation plan

2. Indicators (Measurables)

3. Action taken

4. Review of action taken

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1^st Step – “Initial-Clean” Diagnosis Checklist

2^nd Step – “Countermeasure for source of contamination & hard-to-access area” Diagnosis Checklist

3^rd Step – “Preparation of tentative autonomous maintenance standards” Diagnosis Checklist