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CPTB 07 Autonomous Maintenance Step 1 02 SR TR

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Autonomous Maintenance Stage 1
Autonomous Maintenance Step 1
Goals Target groups
Practical advice
Forms 
Check lists 
The 7 steps
of AM
Reasons for doing AM 
Methods and tools
Autonomous
 Maintenance 
Definition of AM 
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Autonomous Maintenance Stage 1
Autonomous Maintenance 
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Autonomous Maintenance Stage 1
Situation prior to TPM® 
 
Tasks of maintenance 
Tasks of manufacturing 
- Cleaning and lubrication
 Maintenance and inspection
 Preventive Maintenance 
- Overhaul
- Repairs (after breakdowns) 
 Cleaning 
 Reacting to unplanned stoppages
- Production 
Situation after the introduction of TPM® 
Tasks of maintenacne
Tasks of manufacturing
 Preventive
 Maintenance
Condition-based
 Maintenance 
- Overhaul, Improvements
- Training of operators 
- Repairs (after breakdowns) 
Cleaning, maintenance,
 inspection, lubrication
- Production 
Change of responsibilities through AM
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Autonomous Maintenance Stage 1
Goals of the Autonomous Maintenance (1)
Increasing machine / equipment efficiency through timely maintenance, servicing, and by carrying out improvements, whereby focus is given to the role of the machine operator.
Machine / equipment efficiency is positively influenced by:
 Restoring desirable machine / equipment conditions (Step 1)
 Improving machine / equipment conditions (Step 2)
 Maintaining improved machine / equipment conditions (Step 3)
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Autonomous Maintenance Stage 1
By indroducing Autonomous Maintenance, the degree of responsibility assumed by operators concerning their own operational processes is steadily increased.
Here a comparison between private and corporate maintenance activites:
Tyre pressure
Coolant 
Oil level 
Fuel 
Cleanliness 
Light
Cleanliness 
Tools o.k? 
Filter 
clean?
Cooling agent available? 
Sufficient lubrication?
Private activities: 
Corporate activities:
Goals of Autonomous Maintenance (2)
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Autonomous Maintenance Stage 1
Having received education and training within the scope of Autonomous Maintenance, operators can independently perform certain maintenance tasks and smaller repairs.
Change tyre
Check tyre pressure
Change 
spark plugs
 
Refuel
Refill coolant 
Change lamp
Refill hydraulic oil
Change chuck 
Change filter
Tighten loose 
screws 
Private activities: 
Corporate activites:
Check and change coolants 
Check service points
Goals of Autonomous Maintenance (3)
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Autonomous Maintenance Stage 1
Quelle: JIPM (Japan Institute of Plant Maintenance)
7 Steps of Autonomous Maintenance
Independent servicing and maintenance of machines
and equipment by operators
Initial cleaning of machines
and equipment
Prevention of contamination,
improvement of servicing
Standards for cleaning
and servicing
Training of employees to do
independent servicing
Independent servicing
by operators
Standards for 
safeguarding processes
Full application of Autonomous
Maintenance
* Initial cleaning, lubrication
* Marking of defects
* Restoring desirable conditions
* Elimination of leakage
* Improving access to check points
* Eliminating sources of dirt and contamination
* Use of checklists and check plans
* Visual management at machine
* Surroundings (standards for cleanliness and neatness)
* Develop knowledge of machine design
 and functions
* Train skills for independent servicing
* Independent servicing using
 check lists and maintenance plans
* Deepen knowledge of
 servicing and corrective
 maintenance
* Full use and continuous improvement
Cleaning is inspection!
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Autonomous Maintenance Stage 1
Initial cleaning of machines
and equipment
Prevention of contamination,
improvement of servicing
Standards for cleaning
and servicing
Training of employees for
independent servicing
Independent servicing
by operators
Standards for
safeguarding of processes
Full application of Autonomous
Maintenance
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2
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7 Steps of Autonomous Maintenance
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Autonomous Maintenance Stage 1
Cleaning = Inspection!
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Autonomous Maintenance Stage 1
Cleaning = Inspection!
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Autonomous Maintenance Stage 1
Flow diagram initial cleaning 
1. Step Create cleaning and lubrication plans
2. Step 
 Preparatory discussion 
 by the team 
 Distribution 
 of the cleaning tasks
 Preparation of a list of abnormalities
3. Step 
 Initial cleaning
 Lubricate according to plan 
 Marking and registration 
 of abnormalities
4. Step 
 Compile maintenance plan
 Correction of abnomralities
- Regular cleaning and lubrication 
Autonomous Maintenance Step 1 
Initial cleaning of the 
machines and equipment 
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Autonomous Maintenance Stage 1
Example: Cleaning plan object: Automatic lathe 03 
clean protective covers with rags
clean bed track guide with brush 
wipe off glass of oil-level gauge with rags 
wipe off hydraulic system with rags
remove chps from drip tray and clean with hand-brush 
Autonomous Maintenance Step 1 
Basic cleaning of the 
machines and plants 
clean water container
with steam jet cleaner 
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Autonomous Maintenance Stage 1
Autonomous Maintenance Step 1 
Basic cleaning of the 
machines and plants 
Example: Checklist for cleaning materials
Object: 03 Type: Automatic Lathe
Tools:
Screw driver
Allan key
Spanner
Cleaning Materials
Rag
Cleaning detergents
Broom
Dustpan & Brush
Utensils:
Brush
Scraper
Water Tank
Steam Jet Cleaner
Vacuum Cleaner
Protective Clothing:
Overalls
Safety Glasses
Rubber Boots
Gloves
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Autonomous Maintenance Stage 1
Autonomous Maintenance Step 1 
Basic cleaning of the 
machines and plants 
Example: Cleaning plan for equipment surroundings: Automatic lathe 03 
03
MIN
MAX
MIN
MAX
MIN
MAX
Trolley 
Trash can 
Well-cleaned 
floor 
Test and 
measuring tables 
Tools 
Pallet 
Wire baskets 
Workbenches 
Jigs 
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Autonomous Maintenance Stage 1
Object: 03 Designation: Automatic lathe 
Measuring station 
 Are the measuring instruments 
 located at the correct place?
 Are the measuring stations clean?
- Are all documents up to date?
Defects/ rework 
 Do the containers stand at the
 correct place? 
 Are the containers clearly marked? 
Materials allocation 
 Are all materials found at the work- statíon in the correct quantity? 
 Are pallets, containers in a
 tidy condition? 
Disposal 
 Are the trash cans at 
 the correct places? 
 Have the trash cans been emptied?
 Have all ashtrays been emptied? 
 Are chip containers and trash cans 
 in order? 
 Is emulsion container clean? 
Work area around the machine 
 Are the markings still visible? 
 Is everything located at 
 the intended place? 
- Is the floor clean?
Example: Check list for the surroundings of the machine 
Autonomous Maintenance Step 1 
Basic cleaning of the 
machines and plants 
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Autonomous Maintenance Stage 1
Autonomous Maintenance Step 1 
Basic cleaning of the 
machines and plants 
Example: Schematic plan for lubrication, automatic lathe 03 
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Autonomous Maintenance Stage 1
Autonomous Maintenance Step 1 
Basic cleaning of the 
machines and plants 
Object: 03 Type: Automatic Lathe
Mechanical systems:
Secure metal covers
Tighten hydraulic connectors
Tighten pneumatic connectors
Replace missing screws
Remove chips from moving parts (do not use pressurized air)
Check pneumatic hoses for leaks
Identify and eliminate leakage
Pay attention to excessively loud noises
Visually check all conveyors and transport belts
Visualyl check all rubber seals on doors and windows
Check servicing points
Elektrical systems:
Change filter
Secure loose cables
Check correct fitting of limit switch
Check that all appliances are properly fastened
Check function of machine lighting
Check control lights
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Autonomous Maintenance Stage 1
Autonomous Maintenance Step 1 
Basic cleaning of the 
machines and plants 
Countermeasure: Removal of abnormalities
1. Marking of abnormalities with colored small cards 
2. Register abnormalities 
1.Hydraulic pipe 
leaky 
2 Sheet metal 
 bent 
3. Lamp 
defectively 
3. Remove abnormalities 
Activity plan Nr.01
Current condition: 
Hydraulic pipe leaks 
Action: 
Seal hydraulic pipe 
Order: Date: 
4. Check measures 
Abormalities to be corrected: 
1. Seal hydraulic pipe
Order done:
04 / 00
2. Straighten sheet metal
05 / 00
3. Replace lamp 
05 / 00
Clark
Smith 
Miller
Initial cleaning of the machines and plants 
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Autonomous Maintenance Stage 1
Autonomous Maintenance Step 1 
Basic cleaning of the 
machines and plants 
Example: Auditing questionnaire for Step 1 of the Autonomous Maintenance 
clear
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No.
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Items to check 
Points 
Are cleaning plans and check lists for initial cleaning of the machine present and complete?
Are all cleaning tools and agents contained in the check list present at the work station ?
Have unnecessary items, jigs, are tools etc. been removed from work station and its surroundings?
Has the machine been cleaned, including protective covers and supplementary jigs? 
Are the cooling agent (emulsion) and the coolant tank in a normal condition? 
Taking into account condtions of operation, is the work station and its surroundings free of contamination, dust, oil, fat, and chips?
Are lubrication plans and check lists for lubrication available at the machine? 
Has the machine been serviced correctly according to the lubrication plan?
Has the machine been inspected according to the inspection plan, and have abnormalities been marked with coloured tags? 
Have all operators involved in TPM activities been trained in Step 1 of Autonomous Maintenance, and has this been documented? 
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