Autonomous Maintenance (Jishu Hozen) refers to TPM activities that involve operators in maintaining their own equipment, independent of the maintenance department. Activities in an AM program include: daily inspections, lubrication, parts replacement, simple repairs, abnormality detection and precision checks. The goals of the program are to prevent equipment deterioration, restore equipment to its ideal state, and establish basic conditions needed to keep equipment well maintained. AM is one of the most important building blocks in any TPM program.

This PowerPoint presentation is developed by our JIPM-certified TPM consultant. It is packed with diagrams, examples and practical tips and can also be used to train shopfloor staff participating in autonomous maintenance activities.

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Note: This training package includes:
1. Autonomous Maintenance training presentation (PowerPoint format)
2. The Seven Steps of Autonomous Maintenance poster (PDF format, in color and monochrome, printable in A3 size)
3. Autonomous Maintenance Framework poster (PDF format, in color and monochrome, printable in A3 size)
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LEARNING OBJECTIVES

1. Understand the key concepts of TPM and Autonomous Maintenance activities
2. Learn how to implement the Autonomous Maintenance activities, step by step
3. Learn how to use activity boards, meetings and one-point lessons to promote TPM goals
4. Understand the critical success factors in sustaining Autonomous Maintenance activities on the shopfloor

CONTENTS

1. Overview of TPM
•  Common Features of Workplaces with Poor TPM Implementation
•  Machine Failures Have Many Hidden Causes
•  What is TPM?
•  TPM Principles
•  TPM Provides a Basic Foundation for Lean Transformation
•  TPM Eliminates/Reduces Waste
•  Why Is TPM Important?
•  TPM Goals
•  Eight Pillars of TPM
•  TPM Benefits

2. Introduction to AM
•  What is AM?
•  What AM is Not
•  AM is a Paradigm Shift
•  AM Facilitates a Culture Change
•  Characteristics of AM Programs
•  Goals of AM
•  Natural & Forced Deterioration
•  AM Approach

3. Tools of AM
•  3 Key Tools for AM
•  Activity Board
•  Examples of Activity Board
•  What is One-Point Lesson?
•  3 Purposes of One-Point Lesson
•  Philosophy of One-Point Lesson
•  One-Point Lessons as a Cascading Tool
•  Types of One-Point Lessons
•  Examples of One-Point Lessons
•  Four Equipment-related Skills for Operators

4. How to Implement the Seven Steps of AM: The Step by Step Approach
•  7 Steps of AM
•  Step 1: Clean & Inspect
•  Step 2: Eliminate problem sources and inaccessible areas
•  Step 3: Draw up cleaning and lubricating standards
•  Step 4: Conduct general inspections
•  Step 5: Conduct autonomous inspections
•  Step 6: Standardize through visual workplace management
•  Step 7: Implement autonomous equipment management

5. Sustaining AM
•  How to Sustain AM?