Card: The Seven Steps of Autono
Step
Major activities
Thoroughly clean equip
ment and its sur
roundings
1. Initial cleaning
Remove all unnecessary
materials
Write upcoming issues
onto four lists
Remedy sources of
contamination
1. Countermeasures to
sources of contamina
tion
Prevent contaminants
from irregular and unde
sirable dispersion
Improve difficult clea
ning areas to reduce
cleaning times
Conduct education for
lubricating
Develop overall lubricati
on inspection
1. Cleaning and lubricati
on standards
1. Cleaning and lubricati
on standards
Establish lubrication con
trol system
Set cleaning and lubrica
tion standards
By each inspection cate
gory:
Conduct education and
practice
1. Overall inspection
Develop overall inspecti
on
Remedy difficult
inspection areas in
equipment to reduce
required time
Set tentative inspecting
standards
Set autonomous mainte
nance standards and sch
edule to finalize activities
focused on equipment
Faithfully conduct routi
ne maintenance in ac
cordance with standards
1. Autonomous Mainte
nance standards
Move forward aiming at
Zero Breakdowns
Prevent outflow of de
fective products to dow
nstream processes
1. Organisation
Prevent manufacturing
of defective products
Attain process quality
assurance and move
forward aiming at Zero
Defects
Maintain, improve and
pass on current TPM
levels
1. Autonomous mainte
nance
Calculate the Overall
Equipment Effectiveness
(O.E.E.)
Analasis of the failure of
the equipment
en Steps of Autonomous Maintenance
Aims from equipment
perspective
Aims from human
perspective
Expose hidden defects
by removing contami
nants
Become familiar with
group activity by way of
easy tasks such as clea
ning
Restore defective areas
in equipment
Group leaders learn lea
dership
Identify sources of con
tamination
Look at and touch every
corner of equipment to
enhance its care and to
promote curiosity and
questions
Learn Cleaning is inspec
tion
Prevent contaminants
from generating and ad
hering to equipment in
order to enhance relia
bility
Learn motion and
working mechanism of
machinery
Definitely maintain equ
ipment cleanliness so as
to improve maintainabi
lity
Learn methods to
improve equipment
focused on sources of
contamination
Encourage interest and
desire to improve
equipment
Feel pleasure and
satisfaction with
successful achievement
of improvement
Correct difficult lubrica
ting areas
Set rules by oneself and
follow them
Apply visual controls
Know importance of fol
lowing rules and autono
mous supervision
Definitely maintain basic
equipment conditions
(cleaning, lubricating,
tightening) to establish
deterioration prevention
system
Encourage awareness of
ones own roles and
teamwork
Detect and remedy minu
te defects
Learn structure, function
and inspection methods
of equipment to master
inspection skill
Thoroughly apply visual
controls
Master easy servicing
procedures
Improve difficult in
spection areas
Group leaders learn lea
dership through conduc
ting roll-out education
Maintain established
equipment conditions by
means of routine inspec
tion to improve reliability
further
Learn recording, sum
marization and analysis
of inspection data
Assess successful reme
dies achieved in other
processes, and apply
them to similar equi
pment
Understand equipment
as a total system
Totally review visual con
trols
Develop ability to detect
signs of abnormalities to
prevent breakdowns
Preserve equipment in
highly reliable condition
along with operability
and maintainability
Train knowledgeable ope
rators
Realize an orderly shop
floor
Establish autonomous
supervision system con
ducted by PM group
Assess process quality
Train knowledgeable ope
rators on equipment and
quality aiming at new
type of engineering sta
tus
Attain a reliable process
to prevent outflow of
quality defects
Attain autonomous su
pervision within each
operator
Assess quality conditions
Attain a highly reliable
process to prevent manu
facturing of quality de
fects
Predict abnormalities to
prevent breakdowns and
quality defects prior to
occurrence
The O.E.E. shows the
week spots of the equip
ment
Attain Zero Accidents,
Zero Breakdowns
Firmly establish self-su
pervision to be able to
develop factorys strate
gy by SGA groups them
selves without managers
detailed instruction
Move forward aiming at
higher level of produc
tion technology
Detect and resolve ari
sing problems by SGA
groups themselves by
way of short remedial
program
ntenance
Managers supervision and
support
Lead by staying one step
ahead, comprehending
TPM through practice,
and demonstrating with
examples of managers
models
Teach defects of equip
ment
Teach importance of clea
ning, lubrication and ti
ghtening
Teach Cleaning is inspec
tion
Teach motion and wor
king mechanism of ma
chinery
Teach where-where and
why-why analyses to ex
amine problem
Assist in implementing
ideas for improvement
Promptly respond to
work orders
Prepare lubrication con
trol rules
Provide education and
practice in terms of lubri
cation
Teach how to prepare
cleaning and lubricating
standards
Assist actual preparation
of standards
Prepare overall in
spection schedule, check
sheets, manuals, and
other teaching materials
Promptly respond to
work orders
Provide training for easy
servicing
Teach how to improve
difficult inspection areas
by applying visual con
trols thoroughly
Teach inspection data h
andling
Allocate inspection work
between autonomous
and full-time maintenan
ce
Teach basic maintenance
skill and easy machine
diagnosis
Teach examples of break
down prevention
Teach particular function
of each piece of equip
ment to understand equi
pment as a system
Teach quality specifi
cations, quality causes
and quality results along
with their relationship
Teach the five criteria for
ease of observation
Teach the five criteria for
quality assurance
Address matters of quali
ty with cooperation by all
related departments
Assisting with the calcula
tion of the O.E.E.
Assist activities to
maintain, improve and
hand down current TPM
status
Encourage further im
provement of technical
knowledge and skills
Move froward toward
the second generation of
TPM
