General Activities
- Setup Facilitator Practice session
- Develop Minor Stop benchmark by line
- Create a standard Activity Board format and roll it out across the plant
- Create audit templates for each step
- Set up a feedback loop for Breakdowns (BD) to AM inspections
- Develop skills matrix for pilot line team
- Automate Cleaning Inspection Lubrication (CIL) standards
- Involve operators in Planned Maintenance (PM)
AM Step 0
- Train or Refresh members on Step 0
- Train or Refresh members on LOTOTO
- Principle of operation of machine understood by the team
- Identify the Sources of Energy
- Map out Sources of Energy. Apply visual controls
- Identify the LOTO points to lock out the SOE
- Map out LOTOTO Points. Apply visual controls
- Generate OPLs related to SOE / LOTOTO new findings
- Identify training opportunities associated with Equipment Safety
- Training the people on OPLs on how to use Safety F-tags
- Safety F-tags are being generated to highlight abnormalities. Prioritize F-Tag Closure
- 5S training is provided to the team members
- 5S activities are carried out with a focus to improve safety
- Develop the activity board to show the progress
- Training the operator in the OEE Loss Concepts
- Preliminary Step audit completed by the team
- Mid-point Step audit completed by the team
- Step Audit completed by the team
- Step Audit by Line Manager
- TPM Steering Committee does the audit to move on to Step 1
AM Step 1
- Step 1 training is completed for the team members. New employee included
- First 3S’s (Sort, Store, Shine, Standardize, Sustain) of 5S is the main focus of the team
- Basic 5S Markings in area
- OPLs are generated to show before and after pictures of 5S improvements in the area
- Implement Tags Process (Blue), (Red), (Green)
- Deep Clean Activities. Treasures (broken parts) are saved for training purposes
- Develop or Review Preliminary or Existing Cleaning Standard and CheckList
- Develop or Review Preliminary or Existing Inspection Standard and Checklist
- Implement Visual Control Process to facilitate inspection
- Machine parts and systems (gears & electrical system etc.) is being inspected
- Review OPLs developed for cleaning and inspection standards. Generate new OPLs
- Update Activity board created by the team
- Define the responsibilities of the operator according to TPM tools
- Results are shared and understood by team members
- Reduction in minor stops & breakdowns is linked with cleaning and inspection activities
- Preliminary Step audit completed by a team
- Mid-point Step audit completed by team
- Map SOC and HTA
- Step Audit completed by the team
- Step Audit by Line Manager
- TPM Steering Committee does the audit to move on to Step 2
AM Step 2
- Step 1 activities progress is continued Included
- Step 2 training is completed for the team members
- Perform a safety risk assessment Implement ECRS for each SOC
- Prioritize SOC ( volume generated and time to cleaning )
- Implement plan to eliminate SOC
- Implement ERCS for each HTA
- Review Preliminary or Existing Cleaning Standard and the check list
- Review Preliminary or Existing Inspection Standard and the check list
- Before and after pictures showing the improvements to SOC and HTA
- Visual Controls are being used by the team to reduce inspection time
- Training reviewing of Preliminary standards ( Cleaning / Inspection )
- Map of lubrication points
- Preliminary Step audit completed by team
- Mid-point Step audit completed by team
- Step Audit completed by the team
- Step Audit by Line Manager
- Audit is done by the TPM Steering Committee to move on to Step 3
AM Step 3
- Step 1 and 2 activities progress is continuedLubrication conception training
- Perform a safety risk assessment
- Develop the Lubrication Standard and check list
- Implement Visual Control for Lubrication Points
- Lubrication standard training
- Develop and Implement the Lubrication Cart or shadow board for Lubrication tools
- Transfer the lubrication process to AM Review
- Preliminary Cleaning Standard and the check list
- Review Preliminary Inspection Standard and the check list
- Review the visual control
- Training Prioritization Matrix by system to step 4
- Activity board updated daily/weekly to share the result amongst the team members
- Preliminary Step audit completed by team
- Mid-point Step audit completed by team
- Step Audit completed by the team
- Step Audit by Line Manager
- Audit is done by the TPM Steering Committee to move on to Step 4
AM Step 4
- Step 3 activities progress is continued
- Step 4 training is completed for the team members
- General inspection training
- Perform a safety risk assessment
- Understand the equipment structure Identify parts and components of the equipment
- Perform thorough check of all the main functional components
- Identify deterioration areas on the equipment
- Create One Point Lessons
- Produce general inspection manuals
- Training on QM techniques (quality control points)
- Develop the activity board to show the progress
- Preliminary Step audit completed by team
- Mid-point Step audit completedly by team
- Preliminary Step audit completed by team
- Step Audit completed by the team
- Step Audit by Line Manager
- Audit is done by TPM Steering Committee to move on to Step 5
AM Step 5
- Step 4 activities progress is continued
- Step 5 training is completed for the team members
- Perform a safety risk assessment
- Review CIL (cleaning, inspection & lubrication) standards
- Review past breakdowns analysis improvements
- Identify machine Quality control points using QM techniques
- Generate QM matrix Create One Point Lessons Identify areas of quality loss
- 4M training (Man, Method, Machine & Materials)
- Develop the activity board to show the progress
- Preliminary Step audit completed by team
- Mid-point Step audit completedly by team
- Preliminary Step audit completed by team
- Step Audit completed by the team
- Step Audit by Line Manager
- Audit is done by TPM Steering Committee to move on to Step 6