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Autonomous Maintenance
© Operational Excellence Consulting. All rights reserved.
Time
Infant
Mortality
Failures
Useful Life Failures
(Constant Failure Rate)
Wear-Out
Failures
FailureRate
0
Preventive
Maintenance Extends
the Useful Life
An Effective TPM Program Extends
the Useful Life of Equipment
Goals of
Autonomous
Maintenance
Prevent
Equipment
Deterioration
Equipment
Restoration &
Proper
Management
Establish Basic
Conditions
Goals of Autonomous Maintenance
4
3
Set Optimum
Equipment Conditions
2
1
Correct & Restore
Abnormalities
Detect
Abnormalities
Maintain Optimum
Equipment
Conditions
Four Equipment-related Skills for Operators
Check
ActPlan
Do
Examine and
expose problems
Counter and
solve problems
Execute and follow
standards and rules
Prevent recurrence
through
improvement
Autonomous Maintenance Approach
Steps of Autonomous Maintenance
1. Clean and inspect
2. Eliminate problem sources and inaccessible areas
3. Draw up cleaning and lubricating standards
4. Conduct general inspections
5. Conduct autonomous inspections
6. Standardize through visual workplace management
7. Implement autonomous equipment management
7 Steps of Autonomous Maintenance
AM Team Improvement Process
3 Key Tools for AM Team Activities
Who? What? Where?
1. Who does it?
2. Who is doing it?
3. Who should be doing it?
4. Who else can do it?
5. Who else should do it?
6. Who is doing 3-Mu’s?
1. What to do?
2. What is being done?
3. What should be done?
4. What else can be
done?
5. What else should be
done?
6. What 3-Mu’s are being
done?
1. Where to do it?
2. Where is it done?
3. Where should it be
done?
4. Where else can it be
done?
5. Where else should it be
done?
6. Where are 3-Mus’ being
done?
When? Why? How?
1. When to do it?
2. When is it done?
3. When should it be
done?
4. What other time can it
be done?
5. What other time should
it be done?
6. Are there any time 3-
Mu’s?
1. Why does he do it?
2. Why do it?
3. Why do it there?
4. When do it then?
5. Why do it that way?
6. Are there 3-Mu’s in the
way of thinking?
1. How to do it?
2. How is it done?
3. How should it be done?
4. Can this method be
used in other areas?
5. Is there any other way
to do it?
6. Are there any 3-Mu’s in
the method?
The 5W & 1H of Improvement
Overall
Equipment
Effectiveness
Availability
Breakdowns
Setups &
Adjustments
Performance
Reduced Speed
Minor Stops &
Idling
Quality
Defects &
Rework
Startup &
Yield Loss
Six Big Losses
OEE: An Indicator of Equipment Health
Activity
Boards
Meetings
One-Point
Lessons
Autonomous Maintenance
© Operational Excellence Consulting. All rights reserved.
Time
Infant
Mortality
Failures
Useful Life Failures
(Constant Failure Rate)
Wear-Out
Failures
FailureRate
0
Preventive
Maintenance Extends
the Useful Life
An Effective TPM Program Extends
the Useful Life of Equipment
Goals of
Autonomous
Maintenance
Prevent
Equipment
Deterioration
Equipment
Restoration &
Proper
Management
Establish Basic
Conditions
Goals of Autonomous Maintenance
4
3
Set Optimum
Equipment Conditions
2
1
Correct & Restore
Abnormalities
Detect
Abnormalities
Maintain Optimum
Equipment
Conditions
Four Equipment-related Skills for Operators
Check
ActPlan
Do
Examine and
expose problems
Counter and
solve problems
Execute and follow
standards and rules
Prevent recurrence
through
improvement
Autonomous Maintenance Approach
Steps of Autonomous Maintenance
1. Clean and inspect
2. Eliminate problem sources and inaccessible areas
3. Draw up cleaning and lubricating standards
4. Conduct general inspections
5. Conduct autonomous inspections
6. Standardize through visual workplace management
7. Implement autonomous equipment management
7 Steps of Autonomous Maintenance
AM Team Improvement Process
3 Key Tools for AM Team Activities
Who? What? Where?
1. Who does it?
2. Who is doing it?
3. Who should be doing it?
4. Who else can do it?
5. Who else should do it?
6. Who is doing 3-Mu’s?
1. What to do?
2. What is being done?
3. What should be done?
4. What else can be
done?
5. What else should be
done?
6. What 3-Mu’s are being
done?
1. Where to do it?
2. Where is it done?
3. Where should it be
done?
4. Where else can it be
done?
5. Where else should it be
done?
6. Where are 3-Mus’ being
done?
When? Why? How?
1. When to do it?
2. When is it done?
3. When should it be
done?
4. What other time can it
be done?
5. What other time should
it be done?
6. Are there any time 3-
Mu’s?
1. Why does he do it?
2. Why do it?
3. Why do it there?
4. When do it then?
5. Why do it that way?
6. Are there 3-Mu’s in the
way of thinking?
1. How to do it?
2. How is it done?
3. How should it be done?
4. Can this method be
used in other areas?
5. Is there any other way
to do it?
6. Are there any 3-Mu’s in
the method?
The 5W & 1H of Improvement
1. Set TPM
Targets
2. Form a Team &
Collect Data
3. Analyze
Breakdowns &
Suggest
Improvements
4. Track & Record
Performance
5. Achieve & Verify
Targets
6. Report Results
& Recognize Team
Overall
Equipment
Effectiveness
Availability
Breakdowns
Setups &
Adjustments
Performance
Reduced Speed
Minor Stops &
Idling
Quality
Defects &
Rework
Startup &
Yield Loss
Six Big Losses
OEE: An Indicator of Equipment Health
Activity
Boards
Meetings
One-Point
Lessons
© Operational Excellence Consulting. All rights reserved. 3
Operational Excellence Consulting is a management training and consulting
firm that assists organizations in improving business performance and
effectiveness. Based in Singapore, the firm’s mission is to create business
value for organizations through innovative design and operational excellence
management training and consulting solutions. For more information, please
visit www.oeconsulting.com.sg

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TPM: Autonomous Maintenance (Jishu Hozen) Framework Poster

  • 1. Autonomous Maintenance © Operational Excellence Consulting. All rights reserved. Time Infant Mortality Failures Useful Life Failures (Constant Failure Rate) Wear-Out Failures FailureRate 0 Preventive Maintenance Extends the Useful Life An Effective TPM Program Extends the Useful Life of Equipment Goals of Autonomous Maintenance Prevent Equipment Deterioration Equipment Restoration & Proper Management Establish Basic Conditions Goals of Autonomous Maintenance 4 3 Set Optimum Equipment Conditions 2 1 Correct & Restore Abnormalities Detect Abnormalities Maintain Optimum Equipment Conditions Four Equipment-related Skills for Operators Check ActPlan Do Examine and expose problems Counter and solve problems Execute and follow standards and rules Prevent recurrence through improvement Autonomous Maintenance Approach Steps of Autonomous Maintenance 1. Clean and inspect 2. Eliminate problem sources and inaccessible areas 3. Draw up cleaning and lubricating standards 4. Conduct general inspections 5. Conduct autonomous inspections 6. Standardize through visual workplace management 7. Implement autonomous equipment management 7 Steps of Autonomous Maintenance AM Team Improvement Process 3 Key Tools for AM Team Activities Who? What? Where? 1. Who does it? 2. Who is doing it? 3. Who should be doing it? 4. Who else can do it? 5. Who else should do it? 6. Who is doing 3-Mu’s? 1. What to do? 2. What is being done? 3. What should be done? 4. What else can be done? 5. What else should be done? 6. What 3-Mu’s are being done? 1. Where to do it? 2. Where is it done? 3. Where should it be done? 4. Where else can it be done? 5. Where else should it be done? 6. Where are 3-Mus’ being done? When? Why? How? 1. When to do it? 2. When is it done? 3. When should it be done? 4. What other time can it be done? 5. What other time should it be done? 6. Are there any time 3- Mu’s? 1. Why does he do it? 2. Why do it? 3. Why do it there? 4. When do it then? 5. Why do it that way? 6. Are there 3-Mu’s in the way of thinking? 1. How to do it? 2. How is it done? 3. How should it be done? 4. Can this method be used in other areas? 5. Is there any other way to do it? 6. Are there any 3-Mu’s in the method? The 5W & 1H of Improvement Overall Equipment Effectiveness Availability Breakdowns Setups & Adjustments Performance Reduced Speed Minor Stops & Idling Quality Defects & Rework Startup & Yield Loss Six Big Losses OEE: An Indicator of Equipment Health Activity Boards Meetings One-Point Lessons
  • 2. Autonomous Maintenance © Operational Excellence Consulting. All rights reserved. Time Infant Mortality Failures Useful Life Failures (Constant Failure Rate) Wear-Out Failures FailureRate 0 Preventive Maintenance Extends the Useful Life An Effective TPM Program Extends the Useful Life of Equipment Goals of Autonomous Maintenance Prevent Equipment Deterioration Equipment Restoration & Proper Management Establish Basic Conditions Goals of Autonomous Maintenance 4 3 Set Optimum Equipment Conditions 2 1 Correct & Restore Abnormalities Detect Abnormalities Maintain Optimum Equipment Conditions Four Equipment-related Skills for Operators Check ActPlan Do Examine and expose problems Counter and solve problems Execute and follow standards and rules Prevent recurrence through improvement Autonomous Maintenance Approach Steps of Autonomous Maintenance 1. Clean and inspect 2. Eliminate problem sources and inaccessible areas 3. Draw up cleaning and lubricating standards 4. Conduct general inspections 5. Conduct autonomous inspections 6. Standardize through visual workplace management 7. Implement autonomous equipment management 7 Steps of Autonomous Maintenance AM Team Improvement Process 3 Key Tools for AM Team Activities Who? What? Where? 1. Who does it? 2. Who is doing it? 3. Who should be doing it? 4. Who else can do it? 5. Who else should do it? 6. Who is doing 3-Mu’s? 1. What to do? 2. What is being done? 3. What should be done? 4. What else can be done? 5. What else should be done? 6. What 3-Mu’s are being done? 1. Where to do it? 2. Where is it done? 3. Where should it be done? 4. Where else can it be done? 5. Where else should it be done? 6. Where are 3-Mus’ being done? When? Why? How? 1. When to do it? 2. When is it done? 3. When should it be done? 4. What other time can it be done? 5. What other time should it be done? 6. Are there any time 3- Mu’s? 1. Why does he do it? 2. Why do it? 3. Why do it there? 4. When do it then? 5. Why do it that way? 6. Are there 3-Mu’s in the way of thinking? 1. How to do it? 2. How is it done? 3. How should it be done? 4. Can this method be used in other areas? 5. Is there any other way to do it? 6. Are there any 3-Mu’s in the method? The 5W & 1H of Improvement 1. Set TPM Targets 2. Form a Team & Collect Data 3. Analyze Breakdowns & Suggest Improvements 4. Track & Record Performance 5. Achieve & Verify Targets 6. Report Results & Recognize Team Overall Equipment Effectiveness Availability Breakdowns Setups & Adjustments Performance Reduced Speed Minor Stops & Idling Quality Defects & Rework Startup & Yield Loss Six Big Losses OEE: An Indicator of Equipment Health Activity Boards Meetings One-Point Lessons
  • 3. © Operational Excellence Consulting. All rights reserved. 3 Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. Based in Singapore, the firm’s mission is to create business value for organizations through innovative design and operational excellence management training and consulting solutions. For more information, please visit www.oeconsulting.com.sg