Detailed Autonomous Maintenance Plan

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Effectively and efficiently employ machinery, materials and manpower through the use of TPM tools.

AM Step 0 LINK
1 Train or Refresh members on Step 0 ET
2 Train or Refresh members on LOTOTO ET
3 Personal Protective Equipment Identified and trained SHE
4 Principle of operation of machine understood by the team PM
5 Identify the Sources Of Energy AM
6 Map out Sources Of Energy. Apply visual controls AM
7 Identify the LOTO points to lock out the SOE AM
8 Map out LOTOTO Points. Apply visual controls AM
9 Generate OPL’s related to SOE / LOTOTO new findings AM
10 Identify training opportunity related to Equipment Safety AM
11 Training the people on OPL’s on how to use Safety F-tags. AM
12 Safety F-tags being generated to highlight abnormalities. Prioritize F – Tag Closure AM
13 5S training is provided to the team members ET
14 5S activities are carried out with a focus to improve safety AM
15 Develop the activity board  to show the progress AM
16 Training the operator in the OEE Loss Concepts AM
17 Preliminary Step audit completed by team AM
18 Mid-point Step audit completed by team AM
19 Step Audit completed by the team AM
20 Step Audit by Line Manager AM Pillar Team
21 Audit is done by TPM Steering Committee to move on to Step 1 PLT
AM Step 1 LINK
1 Step 1 training is completed for the team members. New employee included ET
2 First 3S’s(Sort,Store,Shine,Standardize,Sustain) of 5S is main focus of the team AM
3 Basic 5S Markings in area AM
4 OPL’s are generated to show before and after pictures 5S improvements in the area AM
5 Implement Tags Process ( Blue ), (Red), (Green) AM
6 Deep Clean Activities. Treasures (broken parts) are saved for training purposes AM
8 Develop or Review Preliminary or Existing Cleaning Standard and Check List AM
9 Develop or Review Preliminary or Existing Inspection Standard and Check list AM
10 Implement Visual Control Process to facilitate inspection AM
11 Machine parts and systems(gears & electrical system etc) is being inspected AM
12 Review OPL’s developed for cleaning and inspection standards. Generate new OPL’s AM
13 Update Activity board developed by the team AM
14 Define the responsibilities of operator according to TPM tools AM
15 Results are shared and understood by team members AM
16 Reduction in minor stops & breakdowns is linked with cleaning and inspection activities AM
17 Preliminary Step audit completed by team AM
18 Mid-point Step audit completed by team AM
19 Map SOC and HTA AM
20 Step Audit completed by the team AM
21 Step Audit by Line Manager AM Pillar Team
Audit is done by TPM Steering Committee to move on to Step 2 PLT
AM Step 2 LINK
1 Step 1 activities progress is continued Included AM
2 Step 2 training is completed for the team members ET
3 Perform a safety risk assessment SHE
4 Implement ECRS for each SOC AM
5 Prioritize SOC ( volume generated and time to cleaning ) AM
6 Implement plan to eliminate SOC AM
7 Implement ERCS for each HTA AM
8 Review Preliminary or Existing Cleaning Standard and the check list AM
9 Review Preliminary or Existing Inspection Standard and the check list AM
10 Before and after pictures showing the improvements to SOC and HTA AM
11 Visual Controls are being used by the team to reduce inspection time AM
12 Training reviewing of  Preliminary standards  ( Cleaning / Inspection ) ET
13 Map of lubrication points AM
14 Preliminary Step audit completed by team AM
15 Mid-point Step audit completed by team AM
16 Step Audit completed by the team AM
17 Step Audit by Line Manager AM
17 Audit is done by the TPM Steering Committee to move on to Step 3
AM Step 3 LINK
1 Step 1and 2 activities progress is continued AM
2 Lubrication conception training PM
3 Perform a safety risk assessment SHE
4 Develop the Lubrication Standard and check list AM
5 Implement Visual Control for Lubrication Points AM
6 Lubrication standard training PM
7 Develop and Implement the Lubrication Cart or shadow board for Lubrication tools PM
8 Transfer the lubrication process to AM PM
9 Review Preliminary Cleaning Standard and the check list AM
10 Review Preliminary Inspection Standard and the check list AM
11 Review the visual control AM
12 Training Prioritization Matrix by system to step 4 ET
13 Activity board updated daily/weekly to share the result amongst the team members AM
14 Preliminary Step audit completed by team AM
15 Mid-point Step audit completed by team AM
16 Step Audit completed by the team AM
17 Step Audit by Line Manager AM
18 Audit is done by the TPM Steering Committee to move on to Step 4
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