STEP 2
STEP1
TOTAL PRODUCTIVE
MAINTENACE STEP 2
AUDIT
Autonomous Maintenance and Focused Improvement
This audit serves as requirement to ensure alignment to JIPM standards and also for progression in
the TPM cluster.
AUTONOMOUS MAINTENANCE STEP 2
The purpose of this audit is to ensure the Step 2 requirements of Autonomous Maintenance are being fulfilled.
The requirements have been cross referenced with the Japan Institute of Plant Maintenance excellence award
criteria.
Rating Scale: major deviation or more = 0, minor deviation= 1, meet expectations =2, exceeding
expectations = 3, superior=4
STEP 2 AM PRACTICAL
REQUIREMENT
One-Point Lessons:
- OPL established for the avoidance of contamination
sources.
- OPL aligned to training of staff through education and
training (skills matrix, training registers)
- OPL aligned to specific use of equipment to prevent
spillage and splatter
- OPL for hard to access, clean, lubricate and inspect
need to be shown and where required Kaizens where
hard to access, clean, lubricate and inspect processes
have been made easier.
Sources and type of contamination Eliminated:
- Map of equipment losses attributed to contamination
sources (plant wide or equipment specific)
- Problem solving evidence shows contamination
evolvement process (7 QC tools applied) and its
reduction. The journey of elimination of
abnormalities needs to be shown.
- Equipment enhancement evidence provided (design
changes made to reduce contamination)
- Shop Floor is uses OPL’s and 7QC tools to address
contamination issues in line with loss maps,
contamination documentation, standardised work
and other visual controls.
- Equipment is free of contamination
Cleaning Map and Cleaning Standard Operation Sheet:
- Cleaning Map revised showing reduction in cleaning
time (20% to 35%) due to reduced contamination
(stopped at source).
- Evidence shown of use of the senses on new cleaning
map where possible to identify contamination (dust,
dirt, residue) and to identify equipment condition).
- All symbols and times are provided on the cleaning
instruction with contamination types outlined on the
equipment or in a separate document. The purpose is
to show the operators the reasons for contamination
SCORE
RESPONSIBLE
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
TPM STEP 1 AUDIT
1
occurring.
Equipment OEE Map for area:
- Specific OEE calculations over set periods that
highlight the improvements in OEE are presented
and can be linked to AM and FI activities.
- Each machine OEE in the pilot area should now be
readily available and a group OEE calculation may be
applied in addition.
Training and Development Matrix:
- Training on 7QC tools has been concluded for the
pilot area
- Pareto analysis is developed by the team on the
losses (team needs to be able to track losses either
electronically or manually).
- Histograms outlining performance may be applied
- Problem solving application by the shop floor needs
to be provided (boards, photos etc.)
- Individual operator skills with tools and are required
(drills, screw drivers, gears, pumps, motors) either to
structured training or company specific training
provided by the pillar heads or assigned TPM
representative. OPL’s may be generated where
required.
Visual Board Institutionalisation:
- Visual board clearly shows the elimination of
contamination at the source.
- Cleaning plan/Level 1 maintenance (when, where,
who) is provided.
- Level 2 – Maintenance personnel only activities are
outlined and scheduled.
- Tagging has ownership and its tracking is evident and
up to date.
Focussed Improvement
and Autonomous
Maintenance Team.
Ownership should reside
with production once
maintenance has defined
the cleaning specifications.
Autonomous Maintenance
Pillar Head
Steering Committee and
Pillar Heads
Evidence requirements must be sought for each point to ensure the documentation is in use and activities.
STEP 1 AM PRACTICE EVIDENCE – SHOP FLOOR
REQUIREMENT
Cleaning Exercise:
- Cleaning exercise is being adhered to in line with the
cleaning instruction for the area/equipment.(The
auditor needs to see this activity)
- Cleaning exercises are conducted according to the
cleaning standard operation sheet.
- Cleaning tools are in their designated locations.
Knowledge Test 1 Pillar Heads or Shop Floor:
Where the most frequent losses and what are are they?
Operator to use the visual board and refer to the loss map
and OEE metrics and explain them
SCORE
RESPONSIBLE
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head/Shop Floor
TPM STEP 1 AUDIT
2
Knowledge Test 1 Pillar Heads:
Explain four of the 7QC tools in detail. What they are and
where they are used and provide examples that are well
explained of where the operators have used the tools to
solve problems.
Explain why the initial cleaning exercise is performed daily?
As a mechanism to inspect and ensure equipment
functioning.
Visual Advice:
Area standards provided with photos of what the area should
look like complete with labelling, markings etc.
Preparation of tools:
- Cleaning tools are in place and are adequate to clean
in accordance with the cleaning instruction. Operator
to explain the use of the tools using the OPL if
necessary
Contamination Sources:
- Operator to discuss the types of contamination in
detail, where they occur, what they are and apply
the 5why technique when requested.
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
Autonomous Maintenance
Pillar Head
FOCUSSED IMPROVEMENT STEP 1-7
FOCUSSED IMPROVEMENT AUDIT
REQUIREMENT
SCORE
RESPONSIBLE
Kaizen A3 Summary Sheet:
Focussed Improvement
- Kaizens for loss reduction are clearly labelled with
Pillar Head
impact in line with the KPI’s established and required.
- Kaizens for cleaning improvement focussing on the
elimination of contamination sources are provided
and the impact detailed accordingly.
- Kaizens have been closed off showing some results
to date of improvement
Stepped FI plan with a list of all projects:
Focussed Improvement
A detailed list of projects, expected completion date,
Pillar Head
responsible parties
Visual Board Update: All projects presented onto the visual
Focussed Improvement
board and tracked as per the weekly meetings. Team
Pillar Head
structures.
Training and Development Matrix: Who has been trained,
Education and Training
what is their level of competence towards TPM? The matrix
Pillar Head
should follow a competency check.
STEERING COMMITTEE REQUIREMENTS
REQUIREMENT
SCORE
RESPONSIBLE
Declaration: A company communication stipulating the
Focussed Improvement
objectives and commitment to TPM.
Pillar Head
FI and AM Team Structures: Officiated organograms outlining
Focussed Improvement
team structures for the AM and FI piilars.
Pillar Head
TPM STEP 1 AUDIT
3
KPI’s: All projects and training are required to have KPI’s
linked to a master KPI allocation. These are then cross
referenced with Kaizen events and Am activities.
TOTAL SCORE
:
PERCENTAGE
:
RESULT
:
Focussed Improvement
Pillar Head
COMMENTS
AUDITORS:
PILLAR HEADS
STEERING COMMITTEE TEAM:
TPM STEP 1 AUDIT
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