Card: The Seven Steps of Autonomous Maintenance

Step	Major activities	Aims from equipment perspective	Aims from human perspective	Managers' supervision and support
Initial cleaning	Thoroughly clean equipment and its surroundings Remove all unnecessary materials Write upcoming issues onto four lists	Expose hidden defects by removing contaminants Restore defective areas in equipment Identify sources of contamination	Become familiar with group activity by way of easy tasks such as cleaning Group leaders learn leadership Look at and touch every corner of equipment to enhance its care and to promote curiosity and questions Learn "Cleaning is inspection"	Lead by staying one step ahead, comprehending TPM through practice, and demonstrating with examples of managers' models Teach defects of equipment Teach importance of cleaning, lubrication and tightening Teach "Cleaning is inspection"
Countermeasures to sources of contamination	Remedy sources of contamination Prevent contaminants from irregular and undesirable dispersion Improve difficult cleaning areas to reduce cleaning times	Prevent contaminants from generating and adhering to equipment in order to enhance reliability Definitely maintain equipment cleanliness so as to improve maintainability	Learn motion and working mechanism of machinery 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	Teach motion and working mechanism of machinery Teach where-where and why-why analyses to examine problem Assist in implementing ideas for improvement Promptly respond to work orders
Cleaning and lubrication standards	Conduct education for lubricating Develop overall lubrication inspection Establish lubrication control system Set cleaning and lubrication standards	Correct difficult lubricating areas Apply visual controls Definitely maintain basic equipment conditions (cleaning, lubricating, tightening) to establish deterioration prevention system	Set rules by oneself and follow them Know importance of following rules and autonomous supervision Encourage awareness of one's own roles and teamwork	Prepare lubrication control rules Provide education and practice in terms of lubrication Teach how to prepare cleaning and lubricating standards Assist actual preparation of standards
Overall inspection	By each inspection category: Conduct education and practice Develop overall inspection Remedy difficult inspection areas in equipment to reduce required time Set tentative inspecting standards	Detect and remedy minute defects Thoroughly apply visual controls Improve difficult inspection areas Maintain established equipment conditions by means of routine inspection to improve reliability further	Learn structure, function and inspection methods of equipment to master inspection skill Master easy servicing procedures Group leaders learn leadership through conducting roll-out education Learn recording, summarization and analysis of inspection data	Prepare overall inspection 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 controls thoroughly Teach inspection data handling
Autonomous Maintenance standards	Set autonomous maintenance standards and schedule to finalize activities focused on equipment Faithfully conduct routine maintenance in accordance with standards Move forward aiming at Zero Breakdowns	Assess successful remedies achieved in other processes, and apply them to similar equipment Totally review visual controls Preserve equipment in highly reliable condition along with operability and maintainability Realize an orderly shopfloor	Understand equipment as a total system Develop ability to detect signs of abnormalities to prevent breakdowns Train knowledgeable operators Establish autonomous supervision system conducted by PM group	Allocate inspection work between autonomous and full-time maintenance Teach basic maintenance skill and easy machine diagnosis Teach examples of breakdown prevention Teach particular function of each piece of equipment to understand equipment as a system
Organisation	Prevent outflow of defective products to downstream processes Prevent manufacturing of defective products Attain process quality assurance and move forward aiming at Zero Defects	Assess process quality Attain a reliable process to prevent outflow of quality defects Assess quality conditions Attain a highly reliable process to prevent manufacturing of quality defects	Train knowledgeable operators on equipment and quality aiming at new type of engineering status Attain autonomous supervision within each operator	Teach quality specifications, 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 quality with cooperation by all related departments
Autonomous maintenance	Maintain, improve and pass on current TPM levels Calculate the Overall Equipment Effectiveness (O.E.E.) Analasis of the failure of the equipment	Predict abnormalities to prevent breakdowns and quality defects prior to occurrence Attain Zero Accidents, Zero Breakdowns Move forward aiming at higher level of production technology	The O.E.E. shows the week spots of the equipment Firmly establish self-supervision to be able to develop factory's strategy by SGA groups themselves without managers' detailed instruction Detect and resolve arising problems by SGA groups themselves by way of short remedial program	Assisting with the calculation of the O.E.E. Assist activities to maintain, improve and hand down current TPM status Encourage further improvement of technical knowledge and skills Move froward toward the second generation of TPM