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 | |
4M Analysis Process
The purpose of this procedure is to define the steps to do a 4M …
Thank you very much for your sharing.
Could you update the Step4-7 AM plan? Thank you a lot.
Thanks for your interest. Currently we are working on creating content for Autonomous Maintenance Steps 4 and up.