General Activities

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

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