TOTAL PRODUCTIVE MAINTENACE STEP 1 AUDIT



|TOTAL PRODUCTIVE MAINTENACE STEP 1 AUDIT |

|Autonomous Maintenance and Focused Improvement |

|This audit serves as requirement to ensure alignment to JIPM standards and also for progression in the TPM cluster. |

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AUTONOMOUS MAINTENANCE STEP 1

The purpose of this audit is to ensure the Step 1 requirements of Autonomous Maintenance are being fulfilled. The requirements have been cross referenced with the Japan Institute of Plant Maintenance excellence award criteria.

Rating Scale: major deviation or more = 0, minor deviation= 1, meet expectations =2, exceeding expectations = 3, superior=4

STEP 1 AM DOCUMENTATION

|REQUIREMENT |SCORE |RESPONSIBLE |

|One-Point Lessons: All one point lessons for the model area are to be completed in | |Autonomous Maintenance Pillar Head |

|line with the JIPM Standards for hard to access, clean, inspect and lubricate. | | |

|One-point lessons for safety aspects to be completed as well for the model area. One | | |

|point lessons linked to the cleaning instruction where required for difficult | | |

|elements are also a requirement. Register of reference numbers for 1 Point Lessons to| | |

|TPM documentation must also be checked. | | |

|Sources and type of contamination: A detailed study with required process sheets for | |Autonomous Maintenance Pillar Head |

|the sources of contamination and the type of contamination. Problem solving | | |

|documentation may be required for sources that are undefined. | | |

|Cleaning Map: Detailed schematic of the model area equipment outlining points for | |Autonomous Maintenance Pillar Head |

|cleaning, cleaning agents and referencing one-point lessons where required in the | | |

|document. | | |

|Cleaning Standard Operation Sheet with time study (standard time): Detailed step by | |Focussed Improvement and Autonomous |

|step process sheet that allows operators to follow the instructions for cleaning | |Maintenance Team. Ownership should |

|according to the pre-defined cleaning standards. This will require the maintenance | |reside with production once maintenance|

|team to determine with production the cleaning operations, equipment required and the| |has defined the cleaning |

|iterative steps to ensure compliance to safety regulations. | |specifications. |

|Training and Development Matrix: Who has been trained, what is their level of | |Autonomous Maintenance Pillar Head |

|competence towards TPM? The matrix should follow a competency check process and | | |

|audits should allow for these checks to occur spontaneously | | |

|Visual Board Institutionalisation: The visual board should serve as the audit hub. | |Steering Committee |

|All requisite documents should be presented close to the line for frequent team | | |

|discussions. This is critical for both pillars and requires a properly specified | | |

|board that draws the attention of the floor visually. The team structures should be | | |

|included as well. 1S and 2S Audits to be included. | | |

Evidence requirements must be sought for each point to ensure the documentation is in use and activities.

STEP 1 AM PRACTICE EVIDENCE

|REQUIREMENT |SCORE |RESPONSIBLE |

|Cleaning Exercise: Cleaning exercise is being adhered to in line with the cleaning | |Autonomous Maintenance Pillar Head |

|instruction for the area/equipment. | | |

|Knowledge Test 1 Pillar Heads or Shop Floor: What are the purposes of 1 point | |Autonomous Maintenance Pillar Head/Shop|

|lessons? Training and development as well as detailed instruction to avoid error | |Floor |

|Knowledge Test 1 Pillar Heads: Explain the measure for TPM Implementation. Overall | |Autonomous Maintenance Pillar Head |

|equipment effectiveness | | |

|Explain why the initial cleaning exercise is performed daily? As a mechanism to | |Autonomous Maintenance Pillar Head |

|inspect and ensure equipment functioning. | | |

|Visual Advice: Area standards provided with photos of what the area should look like | |Autonomous Maintenance Pillar Head |

|complete with labelling, markings etc. | | |

|Tag Register with Tag Count tracked over time: Tags are tracked. Dates for the | |Red Tags – AM Pillar Head and White |

|tagging register must be validated to ensure daily checks with comments. Online | |Tags – FI Pillar Head |

|registers may be provided with comments. | | |

|Preparation of tools: Organisation evident of tools and production items in use as | |Autonomous Maintenance Pillar Head |

|per agreed standardised defined through the sorting process | | |

|Lists of hard to Clean, Lubricate, Inspect and Tighten are evident and available on | |Autonomous Maintenance Pillar Head |

|the visual boards with reference to one point lessons: Detailed aspects to be covered| | |

|by 1 point lessons. | | |

FOCUSSED IMPROVEMENT STEP 1-7

FOCUSSED IMPROVEMENT AUDIT

|REQUIREMENT |SCORE |RESPONSIBLE |

|Kaizen A3 Summary Sheet: A company specific Kaizen A3 sheet may be developed | |Focussed Improvement Pillar Head |

|(exampled can be found in the CII reference manual for Kobetsu Kaizen).Inclusion of | | |

|the benefit, process and problem and outcome are imperative | | |

|Stepped FI plan with a list of all projects: A detailed list of projects, expected | |Focussed Improvement Pillar Head |

|completion date, responsible parties | | |

|Visual Board Update: All projects presented onto the visual board and tracked as per | |Focussed Improvement Pillar Head |

|the weekly meetings. Team structures. | | |

|Evidence of 7 QC tools: Ishikawa, Cause and Effect Matrix, FMEA, Control Charts, Run | |Focussed Improvement Pillar Head |

|Charts for improvement tracking | | |

|Training and Development Matrix: Who has been trained, what is their level of | |Education and Training Pillar Head |

|competence towards TPM? The matrix should follow a competency check. | | |

|STEERING COMMITTEE REQUIREMENTS |

|REQUIREMENT |SCORE |RESPONSIBLE |

|Declaration: A company communication stipulating the objectives and commitment to | |Focussed Improvement Pillar Head |

|TPM. | | |

|FI and AM Team Structures: Officiated organograms outlining team structures for the | |Focussed Improvement Pillar Head |

|AM and FI piilars. | | |

|KPI’s: All projects and training are required to have KPI’s linked to a master KPI | |Focussed Improvement Pillar Head |

|allocation. These are then cross referenced with Kaizen events and Am activities. | | |

TOTAL SCORE :

PERCENTAGE :

RESULT :

COMMENTS

AUDITORS:

PILLAR HEADS

STEERING COMMITTEE TEAM:

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STEP 1

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STEP1

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