STEP 3

TOTAL PRODUCTIVE
MAINTENANCE STEP
3 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 3

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 3 AM CLEANING, INSPECTION AND LUBRICATION STANDARDS

REQUIREMENT SCORE RESPONSIBLE

Details of cleaning and inspection standards: Autonomous Maintenance
- Visuals in place, eg: flow direction marks, bolt match Pillar Head
mark, pressure gauge range marking, colour coded ______
pipes.

- Has the range of the cleaning and inspection ______

responsibilities been decided?

- Are the methods and tools ______

for cleaning and inspection decided?

- Is the period and time for cleaning and inspection set ______
appropriately?

- Cleaning standards are specific to this machine and is ______

the object of cleaning and inspection clarified?

- Is the cleaning status recorded on check sheets and is ______

this conscientiously observed?

- Is inspection using senses evident based on set ______

standards (kpa, Nm, mm)

- Training and clarity among members ______

Details of oiling standard: Autonomous Maintenance

- Has the range of the Division of oil responsibilities Pillar Head
been decided? ______

- Are the oiling methods and tools

decided and in a fixed location and near the machine ______
(5S of the storage location)?

- Are the period and time set appropriately? ______

- Are the type, quality and quantity of oil decided? ______

TPM STEP 3 AUDIT 1

 - Is the objective of oiling clarified? ______

- Is the oil easy to see and is the oiler functioning ______

normally?

- Is the oiling inlet dirty? Also, are means being devised ______
to prevent it from being dirtied?

- Is a check sheet used to keep records and is this done ______

conscientiously?

- Is the lubrication standards set? (How much, who, ______

why, How)

- Current type of lubrication analysed? ______

Status of autonomous maintenance activities: Autonomous Maintenance

- Are the overall schedule and the current month Pillar Head
schedule clearly defined? ______

- Is a record documenting losses being kept so that

problems can be reduced? ______

- Are the results of countermeasures made apparent

through Kaizens or OPLs? ______

- Are standards created in meetings and is the

importance of observing these standards thoroughly ______
communicated?

Evidence requirements must be sought for each point to ensure the documentation is in use and activities.

STEP 1 & 2 AM FOLLOW UP ON SOURCES OF CONTAMINATION AND HARD TO AREAS

REQUIREMENT SCORE RESPONSIBLE

Initial cleaning: Autonomous Maintenance
- Are clean conditions being maintained? ______ Pillar Head

- Is "Cleaning is Inspection" being observed and are

problems being identified? ______

- Are team members identifying problems with greater

detail and is the next step after improving the skill of ______
members understood?
Sources and type of contamination: Autonomous Maintenance
- Are improvements being made to oiling and are these Pillar Head
improvements leading to increased maintainability? ______

- Are plans being drafted again for those items which

did not achieve adequate results from the
TPM STEP 3 AUDIT 2
 countermeasures? ______

- Are further measures needed? (Are any omissions in

the countermeasures?)
Knowledge Test 1 Pillar Heads or Shop Floor: Autonomous Maintenance
Where the most frequent losses and what are they? Pillar Head/Shop Floor
Operator to use the visual board and refer to the loss map
and OEE metrics and explain them
Knowledge Test 1 Pillar Heads: Autonomous Maintenance
Explain four of the 7QC tools in detail. What they are and Pillar Head
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? Autonomous Maintenance
As a mechanism to inspect and ensure equipment Pillar Head
functioning.
Visual Advice: Autonomous Maintenance
Area standards provided with photos of what the area should Pillar Head
look like complete with labelling, markings etc.
Preparation of tools: Autonomous Maintenance
- Cleaning tools are in place and are adequate to clean Pillar Head
in accordance with the cleaning instruction. Operator
to explain the use of the tools using the OPL if
necessary
Contamination Sources: Autonomous Maintenance
- Operator to discuss the types of contamination in Pillar Head
detail, where they occur, what they are and apply
the 5why technique when requested.

FOCUSSED IMPROVEMENT STEP 1-7

FOCUSSED IMPROVEMENT AUDIT

REQUIREMENT SCORE RESPONSIBLE

Kaizen A3 Summary Sheet: Focussed Improvement
- Kaizens for cleaning, inspection and lubrication Pillar Head
improvements are provided ______

- Kaizens for loss reduction are clearly labelled with

impact in line with the KPIs established and required. ______

- Kaizens for cleaning improvement focussing on the

elimination of contamination sources are provided
and the impact detailed accordingly. ______

- Kaizens for standard identification? ______

- Kaizens have been closed off showing some results

to date of improvement ______

TPM STEP 3 AUDIT 3

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 pillars. Pillar Head
KPIs: All projects and training are required to have KPIs Focussed Improvement
linked to a master KPI allocation. These are then cross Pillar Head
referenced with Kaizen events and Am activities.

TOTAL SCORE :

PERCENTAGE :

RESULT :

COMMENTS

AUDITORS:

PILLAR HEADS

TPM STEP 3 AUDIT 4

STEERING COMMITTEE TEAM:

TPM STEP 3 AUDIT 5