The document outlines a 7-step route for the Autonomous Management pillar. It begins with initial cleaning and planning activities, including cleaning standards and tagging. Steps 2-4 focus on eliminating sources of dirt/difficulty in cleaning, inspecting areas, and labeling items. Step 5 creates and maintains cleaning, inspection, and lubrication standards. Step 6 introduces autonomous inspections using checklists. Step 7 promotes continuous improvement through autonomous teams and standard reviews. The overall route moves from initial setup to autonomously maintaining standards.

1. WCOM 25.02.05
The route for Autonomous Management
Initial cleaning
1. Autonomous Management Planning
2. Remove all items from the workplace that are not needed and
leave only the ones you really need to perform your task
3. Arrange items/tools/carriers etc. so they are easy to use
4. Initial cleaning and tagging preparation and planning
5. Initial cleaning activities and map the current standards
6. De-tagging activities and promotion of continuous tagging
7. Introduction of first temporary standard
1
1. Analyze sources of dirt and difficult-to-
clean areas
2. Implement solutions, update cleaning
standard, monitor results
3. Improve difficult-to-inspect areas
4. Label all items/tools/carriers etc so that
anyone can find them and put them away
Eliminate sources of dirt and
difficult to clean & inspect areas
2
1. Have leaders study the machine
2. Train operators
3. Apply everything learned about the
machine and point out problems
4. Promote visual management
5. Define inspection standards
6. Check results
General inspection
4
Create and maintain cleaning,
inspection & lubrication standards
1. Create and maintain cleaning and
inspection standards
2. Study the lubrication system
3. Simplify the lubrication system
4. Create a visible lubrication system
5. Introduce a lubrication schedule
6. Train the operators
7. Monitor results
3
Autonomous inspection
5
Standardization
6
Autonomous Management
7
1. Create autonomous teams and promote
continuous improvement
1. Review/improve cleaning and
lubrication standards
2. Integrate maintenance&quality
inspection points
3. Implement checklists for autonomous
inspection
4. Promote a Team Meeting system.
5. Improve visual management and
operating level.
6. Check results
1. Collect contents/standards of operators
work and reviewing them
2. Define and improve what has not been
initiated regarding efficiency and
standardization
3. Create Operator Manuals and work
Instructions
AM

2. WCOM 25.02.05
The route for Planned Maintenance Pillar
Understand Current Conditions
1.1 – Understand Cuurent Conditions
•Update Machine List
•ABC Machine Classification
•Losses definition
•Maintenance policy definition
•Break Down deployment
1
Restore Basic Conditions
2
4.1 Build up the TBM system
•Define and/or review the
TBM system
•Define and/or review the
Back-up routines
•Start teams for RCM/FMECA
4.2 Support and train AM on
TBM Plans
TBM System Definition
(Periodical Maintenance)
4
Maintenance Informative System
1. Define Visual performance indicators
2. Define BD reoccurrence control system
3. Redefine maintenance department layout and
organization
4. Define policy for BD analysis expansion and implement
5. Define machine documents management system
6. Build up an inspection plan (dynamic inspection)
7. Train the operator and delegate inspection (bolts and
nuts, transmit ion system, pneumatic and hydraulic )
8. Define Spare Parts Policy and start pilot team on spare
parts optimization.
9. Initial Maintenance Cost Control (corrective,
preventive,etc)
3
CBM System Definition
(Predictive Maintenance)
5
Evaluate Planned
Maintenance System
6
1. Carry on the infinite loop concept
2. Apply Reliability Engineering Concepts
3. Develop a maintenance cost control
system
1. Define CBM tools and plan
2. Train the maintenance people
3. Research for new technologies
1.2 Establish Goals
•Targets definition / BD Reduction Plan
•Define planned maintenance Master Plan
2.1 Autonomous Maintenance Support
•Define tag removal flow and responsibilities
•Provide easy to clean / lubricate solutions
•Eliminate Hard Access Places and Dirt Sources
•Remove the tags related to maintenance
•Provide number of lubricants simplification
•Train the operator on lubrication and Inspection
•Build up maintenance skill matrix
2.2 Improve Weak Points
•Start a pilot on Break Down analysis
•Carry on Break Down reduction teams
PM

3. WCOM 25.02.05
The route for Focused Improvement Pillar
Assess the current situation 1. Understand the Volume Mix
2. Define OEE losses & (re)train operators
3. Validate & follow up daily the OEE losses
1
1. Volume Deployment
2. OEE Deployment (Set up deployment if
required)
3. Process Waste Deployment (Set
up,over usage,trim,
drooling,wrapping,left on the core,top
waste from Total Waste-QM)
4. QA Matrix (understand impact of the
4M)
Deployments, 2nd level
2
1. X matrix on Short Stop recurrence
2. Productivity Deployment
3. Man / Machine detachment
4. Teams for productivity & flexibility
improvement
5. Layout Improvement
Breakthrough on productivity
& flexibility
4
Restore & improve current standards 1. Teams to eliminate OEE losses
2. Teams to reduce Process Waste
3
Build up the zero loss system
5
1. Implement the Continuous Control
System on all machines to follow up
OEE losses.
2. Anomalies reoccurrences follow up
3. Implement Set up System (Correlate Set
up types with procedures & Compare
actual results vs. standards)
4. Use Benchmarking to set new World
Class Targets
FI

4. WCOM 25.02.05
The route for Quality Maintenance
Assess current situation
1. Define Key Quality Performance
Indicators & Targets, incl. Long-term.
Collect initial/historical data
2. QA Matrix for Defects at Plant Level
(continuous update & improvement) -
Identify the Critical Processes
3. Classify Defect modes (based on
historical data & other's experience)
4. Install a data collection system
(aligned with critical processes) /
improve data collection system (level
of details, etc)
1
1. QA Matrix for defect modes at machine
level (aligned with critical process,
continuous update & improvement)
2. Restore 5M conditions
3. Check the results
4. Claim deployment (including Targets
settings & team planning)
5. Defect Waste deployment (including
Targets settings & team planning)
Restore Basic Conditions /
Deploy Quality losses
2
1. Analyze chronic losses (combined
causes)
2. Eliminate chronic losses using adequate
tools (PM analyses, FMEA, statistical
analyses, etc)
3. Identify & "deploy" potential losses
4. Eliminate potential losses using
adequate tools (PM analyses, FMEA,
statistical analyses, etc)
5. Further support SPC - analyze
correlation between process conditions
& defects
6. Prevent potential defects
Eradicate Chronic &
Potential losses
4
Eradicate Repetitive Losses
(Sporadic)
1. Eliminate sporadic losses - defect reduction
2. Eliminate sporadic losses - over-usage
reduction
3. Analyze & improve Measurement System
4. Restore / Introduce SPC
5. Improve capability
6. Quality Daily Meeting & Control System
3
Build the Zero Defect System
5
Improve the Zero Defect System
6
Maintain the Zero Defect System
7
1. Regular review of conditions
implementation status (loop also with
losses indicator)
1. Implement the QX & QM matrixes
(continuous update & improvement)
2. Identify the Q points & Q factors
3. Formalize the links with other Pillars
4. Assess defects/claims analysis
efficiency through the X matrix for
defects/claims
5. Optimize SPC system
1. Apply the "5 questions for zero defect"
2. Improve accordingly the identified
conditions (capability measurement of Q
factors)
3. Poka-Yoke systemization
4. Reduce time & resources needed to
maintain zero defects conditions
QM

5. WCOM 25.02.05
The route for Education & Training Pillar
Develop Strategy
1. Develop Strategy
2. Develop objectives / goals with link to
factory KPIs
1. Review link of factory losses to
training (man & method losses)
2. Review E&T Pillar developmental
needs (see yearly goals below)
3. Review support requirements of
other pillars
3. Define Performance Indicators and
Performance Targets that link to objectives /
goals
1
1. Identify Skills Scale
2. Identify Skills framework i.e. training
areas, skills listing, definition and
stratification of skills (A,B,C)
3. Determine skill ideals / targets by
position/role and process areas
4. Determine actual skill levels of
employees and process areas.
5. Determine skill gaps of employees and
process areas
Identify Skill framework
2
1. Determine skills that require training;
prioritize
2. Develop timelines for training delivery
3. Determine trainees & trainer
Develop the training plan
4
Link factory losses to skills & gaps 1. Cooperation with other pillars (FI, Cost,
QM) to understand the losses
2. Link the skills & gaps to the Factory losses
3
Develop Training contents & trainers
Deliver Training
5
Evaluate & Check
6
Improve the process
7
1. Analyze pillar performance gaps
2. Countermeasures against gaps
3. Process Improvement - Redesign & Actions
1. Establish training format (benchmarking)
2. Establish processes which incorporate
all team training outputs into content
libraries; maintain document control and
ISO 9000 support.
3. Establish document control of training
material & Operational work instructions.
4. Determine gaps in required Training
Content
5. Develop or acquire training content
(locally, VMS, vendors, etc.)
6. Develop / Improve Train the Trainers
process
7. Deliver Training
1. Develop & employ testing methods &
tools for training events (e.g. written
testing, observation, checklist )
2. Develop comprehensive skills
assessment methods (e.g. self-
assessments, supervisor's determine skill
levels, practical assessments/
observation)
3. Apply testing & assessments
4. Determine urgent re-training needs
5. Assess Pillar performance v.s. Pillar
objectives
E&T

6. WCOM 25.02.05
The route for Cost Pillar
Cost
Production cost management
1.1. Performance indicators
1.2. Target settings
1.3. Gap analysis
1.4. Planning
1.5. Follow up
1
2.1. Cost analysis
2.2. Cost allocation
Production cost analysis
2
4.1. Losses calculation (losses x cost)
4.2. Benchmark & potential improvement
4.3. Cost &Benefit analysis
4.4. Optimal cost estimate
→ (update step 1.2)
Benchmark and
cost & benefit analysis
4
Cost drivers identification
3.1. Loss tree creation
3.2. Drivers and formulas
3
Supply chain optimization
5
1. Supply chain design
2. Supply chain modeling
3. Optimal scenarios definition
→ (update step 1.2)
Optimal
cost

7. WCOM 25.02.05
The route for Supply Chain Pillar
Pillar Structure
1. Select members and define responsibilities
2. Receive WCM basic training
3. Fulfil Pillar skill matrix
4. Learn from other factories’ pillars and
supply chain structures
0
1. Define pillar scope
2. Define and map Supply Chain flow &
boundaries
3. Define pillar mission and link with
factory strategy
4. Define supply chain performance
indicators and targets
5. Define the master plan (time-table for
steps 0-5)
Define Pillar Strategy
1
1. Eliminate losses due to lack of
resources and/or overcapacity
2. Production planning optimization
3. Production lead time reduction
4. OT and IF improvement
5. Synchronization of production and WIP
6. Information and material flow
improvement
Restore basic Condition &
Improve production process
3
Collect/understand the data
and map the process
1. Volume deployment
2. Lead time deployment
3. On Time delivery and In full delivery
deployment
4. Supply Chain inventory deployment
5. Complexity and flexibility deployment
6. Supply chain’s logistic cost deployment
7. Information and material flow
2
Restore basic Condition &
Improve Supply Chain
4
Advance Supply Chain
management
5 1. Materials Inbound and Pack Mat
outbound operations improvement
2. Transportation, Warehousing &
Distribution costs and losses reduction
3. Base Materials landed cost reduction
4. Lead Times stabilization
5. Total Supply chain inventory
optimization
6. Total purchase cost reduction
7. Joint improvement programs with
suppliers and customers
1. Improvement and Control systems
(PDCA) for steps 3 and 4
2. Collaborative planning/management
with suppliers and customers
3. Supply chain integration with suppliers
and customers
SC

8. WCOM 25.02.05
The route for Safety and Health Pillar
Assess current Situation
1. Define the Occupational Health and Safety Policy
2. Identify all applicable legal requirements regarding Safety and Health and Prepare
Emergency plans
3. Prepare a plan to accomplish legal requirements & Implement Emergency Plans
4. Define Safety & Health Performance Indicators, actual results (historical data) & long
term targets
5. Prepare & Implement a Data Collection System (Accidents, Incidents, Losses)
6. Define and Implement the Documentation & Records System and data control rules and
flows.
1
1. Deploy Accidents, Incidents & Losses to
define critical areas
2. Define and Implement Safety & Health
Inspection Plan, Standards and Restore
Equipment's Basic Conditions (including
critical parts - Protections, Sensors, Stop
Buttons). Foster Safety tagging.
Restore basic conditions
2
1. Implement Risk Analysis based on
critical areas
2. Define and Implement Standards for
Critical Activities (Operation &
Maintenance) - based on Risk Level
3. Define and Implement Operational
Controls (Eliminate, Signalize, Avoid
Contact, Train, Individual Safety
Equipment) based on Risk Level.
Risk analysis
4
Accident analysis
1. Define and Implement an Accident
Analysis System (Non-Conformances,
corrective and preventive actions
included).
3
Audit system and incident analysis
5
Work place improvement
6
1. Define and Implement the Safety &
Health Audits System
2. Define and Implement Incidents
Analysis System
3. Define and implement regular reviews of
the system (Management System)
1- Define and Implement a Medical
Complaint Data Collection System
2- Define and Implement an Ergonomic
Assessment do identify critical points
3- Define plan to eliminate Ergonomic critical
points
Safety

9. WCOM 25.02.05
The route for Environment Pillar
Define Objectives and
Analyse current Situation
1. Environmental policy
2. Define Environment pillar mission
3. Define Environment pillar objectives and
targets
4. Data Collection
5. Data Analysis
6. Define standard data collection system
1
1. Deployment of environmental losses
2. Decide on priority action
3. Planning of activities
Deploy environmental losses
And plan activities
2
1. Define anomalies collection system
2. Analyze anomalies and define priorities
3. Apply countermeasures and analyze
results
Analyse and eliminate anomalies
4
Restore basic conditions /
implement improvement actions
1. Restore or introduce new standards,
equipment or installations
2. Define inspection standards
3. Continuous checking of standard
conformity
3
Evaluate results and share knowledge
5
Review/implement environmental
Losses prevention system
6
1. Gap analysis between actual situation
and reduced losses
2. Cross fertilization
3. External communication
1- Review/implement environmental
Losses prevention system
Env

10. WCOM 25.02.05
The route for Early Equipment Mgmt
Analyse current situation
1. Identify what type of problems occurred and
what corrective actions were taken
2. Identify current management flow: clarify
current mechanism employed to prevent
problems
3. Define how targets are set to ensure
quality, Maintainability, reliability, safety,
manufacturability and productivity
1
1. Assess the know how situation inside
the factory. Define training needs
2. Establish an EEM System
3. Definition of Check lists for Design
review
4. Development of MP information system
Create the structure
2
1. Implement advanced tools
• QFD
• FMEA
• Life Cycle cost
Development of methodologies
And tools for EEM
4
Pilot project
1. Definition of a pilot project
2. Evaluate new system
3. Modify the system as needed
3
Improve Check lists for
Design Review
5
Improve MP info system
6
General Application
7
1. Expand scope of the system and application to all
areas
2. Optimize life cycle costing and the use of Mp design
3. Identify problems, track problems, MP items used,
lead times and the benefits of the system
1. General Check list for class A, B and C
machines
1. OPL for improvement
2. Technical report
EEM

11. WCOM 25.02.05
The Route for Office Pillar
Initial Inspection
(Analyse current situation)
Understand the current situation
Clean and tag the area for the inspection
Remove the tag and improve the job area
Introduce the temporary standard
Implement audit system (self assessment, management, pillar)
Define a final standard based on visual management
1
Analyze files and documents in use
Eliminate useless documents
Standardize the filling system
Standardize the stationary management system
Check of documents
and filling system
2
Prioritize the improvements needs
Analyze the problem
Make the improvements actions
Control the results
Problem analyses
in the work flow
4
Work flow analyses
List all the activities and tasks
Documents analysis (entry and exit)
Measure the working cargo and loss
Highlight the necessary improvements
3
Standardization
5
Office autonomous
management
6
promote the control “in view” in the offices
prepare the working procedures
implement the offices Automation
Form personal multi-functional
Define Office performance indicator
monitor the results
React to the anomalies
Reduce the papers use
Improve continually the office performances
Off

12. WCOM 25.02.05
Route for Breakdowns Reduction
Historical data collection
Deployment
Define priority / select BD
Identify critical area
Machine cleaning
Anomalies tagging /de-
tagging
Step Target
2 Restore basic
conditions
4 Identify and analyze
Potential Breakdowns.
3 Analyze the Breakdowns
Data collection
Pareto
Gantt
Tag
OPL
SOP
Activities Tools
1 Define problem and target
& understand current
situation.
Define target
Define Performance
Indicator
Master plan
CIL review
TBM review
Operational std review
Define failure Modes
Analyze failure modes
Define countermeasures
Implement
countermeasures
Monitor reoccurrences
Case & Effect
5 whys
WWBLA
PM analysis
X matrix
Technical modifications
Identify potential Failure
Modes
Perform analysis
Define countermeasures
FMECA
FTA
Technical modifications
X matrix
Implement
countermeasures
Monitor occurrences
5 Update Preventive
Maintenance
Summarize cause and
countermeasures.
Write the maintenance
standards
6 Carry out horizontal
expansion
Update CIL
Update TBM
Update CBM
Identify opportunities for expansion
Expand countermeasures
Feed back to design
SOPs
OPLs
T Card
CMMS
SOPs
OPLs
MP info system
Technical modification

13. WCOM 25.02.05
Route for set-up reduction (time and/or scrap)
Activity Tools
Step Target
2 First standard definition
5 Further improve the standard
4 Analyze and solve anomalies
3 Introduction of a system to
register the anomalies
1 Choice of set-up type and
definition of the starting point
and target
6 Adjustments methods
definitions
 Define priority / select setup type
 Define target (time and/or scrap)
 Define Performance indicator (time
and/or scrap)
 Define Master Plan
 Data collection
 Pareto
 Gantt
 Video
 Classify internal x external activities
 Reorganization / rebalancing
 Elimination of evident anomalies
 Communicate / train all operators
 Video
 Travel chart
 From to Matrix
 Man machine diagram
 Check list
 5S.
 Define system to record anomalies
 Follow-up anomalies.
 Anomalies deployment
 Analyze the anomalies
 Implement countermeasures
 Decompose into micro activities
 Classify and analyze the micro activities
 Implement improvement solutions
 ECRS
 LCA
 Analyze current adjustment methods
 Define adjustment standards
 Update setup standard
 Train all operators
 Include standard on ‘setup system’
 Data collection
 Pareto.
 Pareto
 5 whys
 5S
 Technical modifications.
 Video
 OPLs/SOPs
 Poka yoke
 Man Machine diagram
 Check list

14. WCOM 25.02.05
Route for short stops reduction
Activity Tools
Step Target
2 Restore basic condition and
set standards
5 Set standards in order to
consolidate the gains
4 Implement countermeasures
and monitor results
3 Study short stops and
identify root causes
1 Identify and describe short
stops
 Understand the problem
 Define failure mode
 Implement data collection
 Analyze data collection
 Describe the process
 Data collection
 Pareto
 5W +1H
 Story board
 Identify critical areas
 Cleaning and tagging
 Restore basic condition
 Restore operational procedures
 Monitor results
 Tag
 CIL
 OPL
 SOP
 Re-classify remaining short stops
 Understand and describe short stops
circumstances
 Analyze short stops and identify root
causes
 Define countermeasures
 Define action plan
 Implement countermeasures
 Train the operators
 Monitor results
 Define and implement standards for AM
and PM
 Control reoccurrences
 Monitor results
 AM inspection stds
 TBM and CBM
 X-matrix
 MP info system
 Cause & effect
 5 whys
 PM analysis
 WWBLA
 X-matrix
 Gantt chart
 Technical modifications
 OPLs
 SOPs.

15. WCOM 25.02.05
Route for speed loss reduction
Activity Tools
Step Target
2 Restore basic condition on
critical areas and set
standards
5 Analyze and solve anomalies
4 Introduce a system to record
anomalies
3 Define temporary standards
and provide trainings
1 Quantify speed loss and start
data collection
 Split machine by sections and define technical
speed
 Identify gaps between technical speed and current
speed.
 Identify bottlenecks
 Start data collection system
 Define a performance indicator and targets
 Start updating the performance indicator
 Data collection
 Identify critical areas
 Cleaning and tagging
 Restore basic condition
 Restore operational procedures
 Tag
 CIL
 OPL
 SOP
 Define temporary standard for every job
 Define operator best practice including ramp-up
and ramp down
 Train the operators
 Define a system to record anomalies
 Define who, what, when
 Train the operators
 Follow-up the system
 Carry-out a priority analysis of the anomalies
 Identify countermeasures
 Implement countermeasures
 Introduce follow-up table
 Set the machine board
 Pareto
 Cause & Effect
 5 whys
 PM analysis
 Follow-up table
 SOPs
 Anomalies data collection
6 Technical speed attainment
 Measure gap between technical and standard for
each machine component
 Detect weak points
 Attack weak points
 Stabilize results and update the follow-up table
 Technical modification
 LCA

16. WCOM 25.02.05
Activities Tools
•Define priority / select skill to be
improved
•Define performance indicator
•Define target
•Define Master Plan
•Confirm / re-evaluate skill level
Verify training
efficiency
Correct
possible weak
points and
standardize
Define targets and
understand
current situation.
Perform the
trainings
P
D
C
A
Route for Skill Gap reduction
Step Objective
•Skill Matrix
•Pareto
•Control chart
•Gantt
•Questionnaire
•Interview
•Check-list
•Collect available standards and training
material.
•Improve existing documents
•Create missing documents
•Define instructor
•Deliver training sessions
•SOPs/OPLs/Work instructions
•Machine manual
•Film
•Simulator devices
•Evaluate training session (teacher and
training material)
•Evaluate theoretical Skill knowledge
•Evaluate Practical Skill Knowledge
•Follow-up the related losses
•Compare results against targets
•Evaluation form sheet
•Questionnaire
•Interview
•Observation
•Check-list
•Control chart
•Improve further the training material
•Re-apply training sessions
•Re-evaluate training sessions and skills
•Update skill matrix
•Update document system (ISO 9000,
Library, etc...)
•SOPs/OPLs/Work instructions
•Skill matrix
•Library
•ISO 9000