Step

Activity

Goals for Equipment

Goals for Team Members

Leadership & Support by Management

1.  Initial Cleaning

Thoroughly remove dust and contaminants from equipment.

Identify abnormalities and record them in the Abnormality list

Address minor abnormalities

Remove dirt and dust to expose hidden abnormalities .

Restore deterioration and defects.

Identify all the areas that are difficult to operate and maintain.

Get used to team activities through cleaning .

Develop curiosity, interest, and care for equipment through observing and touching equipment.

Learn and acquire basic inspection skills to identify abnormal conditions (Cleaning is Inspection.)

Teach what is the ideal condition and normal vs abnormal.

Teach and show how to identify different types of abnormalities.

Teach "Cleaning is Inspection."

Coach people on selecting their individual improvement.

2.  Address sources of problems

Establish countermeasures for sources of contamination and dispersion of contaminants.

Improve hard-to-clean areas.

Continued inspection and correction of minor abnormalities.

Prevent generation and adherence of contaminants.

Equipment performance improvement through the elimination of selected losses.

Maintain equipment conditions through daily cleaning and inspection.

Apply visual control

Focus on making lasting improvements against problem areas

Increase problem solving capability through basic process for developing, implementing and verifying improvements

Develop understanding of the relation between CI activities and equipment performance

Teach machine motion and transformation processes

Teach where-where analysis, why-why analysis

Define target CI time based on business need.

Teach the proper approach for addressing problem areas

Provide coaching on improvement ideas and methods

. Teach importance of developing standards

3.  Establish Cleaning, Inspection and Lubrication Standards

Provide lubrication skill training.

Conduct general lubrication inspection.

Establish a Lubrication Management System

Set up cleaning, inspection and lubrication standards which can be firmly followed within the designated time.

Restore the Lubrication system to ideal condition

Define activities in which basic conditions (cleaning, lubrication, and oiling) are firmly maintained and deterioration is prevented.

Preparation of standards by the team and follow them.

Learn the importance of following the standards, how to use visual controls and train others

Acquire high degree of ownership for the conditions of the equipment and work area.

Prepare lubrication standards.

Teach lubrication and inspection and give instructions on site.

Teach how to prepare cleaning, inspection and lubrication standards, guiding and supporting preparations.

4. Conduct Overall Equipment /

Process Inspection

For each general inspection subject:

Conduct inspection skill training.

Conduct general inspection.

Improve inspection methods and equipment.

Establish standards for inspection to be conducted firmly within a designated time.

Restore and improve deterioration and defects.

Improve hard-to-inspect areas.

Firmly maintain with daily inspection the restored status from deterioration in order to further improve equipment reliability.

Learn equipment structure, function, and deterioration evaluation criteria through inspection skill training and acquire inspection skill.

Learn and master treatment of simple effects.

Leaders learn leadership through teaching and members learn membership through learning.

Learn how to collect, summarize, and analyze inspection data and recognize its importance.

Prepare general inspection check sheets, manuals and educational materials and provide general inspection training.

Make general inspection schedule.

Process requested repairs promptly.

Teach treatment of simple defects.

Teach visual control and how to implement improvement of hard-to-inspect areas.

Teach how to handle inspection data.

5. Systematize Autonomous Maintenance

Prepare autonomous maintenance standards and calendar to sum up all the activities focused on equipment.

Follow the standards and conduct daily maintenance rigorously

Aim for Zero Breakdowns.

Review results of Focused Improvement (improvement on each piece of equipment) and re-apply them to similar equipment.

Review visual control from overall point of view.

Maintain highly reliable process and equipment with good maintainability and operability.

Materialize such production floor where abnormality is detected easily.

Understand processes and equipment as a total system.

Nurture ability to detect symptoms of abnormality by the 5 senses and to prevent breakdowns and create operators who know equipment well.

Permeate the group's self-managed control.

Determine inspection responsibilities between AM & PM.

Teach basic maintenance skill and simple diagnosis.

Teach case studies in which breakdown was prevented.

Teach structure and functions unique to a process and equipment and have members understand them as a total system.

6 Address Product Quality Standardization

Conduct activities to not let defects pass through.

Conduct activities to not make any defects.

Assure quality by process and equipment and aim for "0" defects.

Review quality assurance items.

Materialize a highly reliable process in which defects are not sent to the next process.

Review quality product conditions.

Materialize highly reliable process and equipment which does not make any defects.

Create operators who know equipment and quality  well and upgrade their level to that of engineers.

Each operator acquires self-managed control.

Teach process quality and quality product (procession) conditions.

Teach relationship between demands-factors-results.

Teach 5 easy-for-QA conditions.

Teach quality assurance through equipment motion and procession principles.

Operation, Maintenance, Quality Assurance, Production Engineering and Product Design Departments share responsibilities for quality.

7. Practice full Autonomous Maintenance

Maintain...

Improve...

Continue the current AM level.

Maintain "0" accidents, "0" defects, and "0" breakdowns and aim for yet a higher level.

Permeate sub-theme (Kaizen) activities, and make problem identification and solution habits for the members.

Predict abnormalities and prevent breakdowns and defects from occurring.

Permeate self-managed control and autonomously  deploy corporate/plant policies into the first line.

Support activities to maintain, improve and continue the AM level.

Further improve technology.

Aim for the second generation AM.

Levels

Required Skills

AM Step

1

  Understanding the importance of cleaning (inspection) and proper cleaning methods

  Understanding the importance to eliminate sources of contamination

  Understanding the importance of proper lubrication

  Ability to discover abnormalities in equipment and components

  Ability to solve abnormalities

STEP 1

STEP 2

2

 Understanding what to look for when checking the machine functioning

  Understanding the right criteria for distinguishing normal from abnormal (judging abnormalities)

  Understanding the relationship between specific causes and specific abnormalities contributing to equipment failure

  Ability to clean and inspect the right locations to maintain equipment performance

  Ability to analyze problems down to root cause and identify countermeasures (trouble shooting)

STEP 3

STEP 4

3

  Understanding the relationship between abnormalities and process conditions

  Understanding the relationship between process conditions and equipment

  Understanding how to set up the right tolerances for static and dynamic precision and how to measure them

  Ability to analyze phenomena

STEP 5

STEP 6

4

  Ability to assist in overhaul repairs

  Ability to reduce set up losses

  Ability to reduce change-over losses

  Ability to take emergency measures

  Ability to update machine conditions and specifications for new initiatives

STEP 7