Detailed Autonomous Maintenance (AM) Master Plan. Steps 1 – 5

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