Total Preventative Maintenance Autonomous Maintenance

Step 0 and 1 (Part 1) Program Initiation

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Definition: “A structured approach that establishes a corporate culture, that

will maximize production system effectiveness”.

Total – Involvement of all functions and

people at all levels of organization.

Productive – Efficient and effective utilisation

of all resources.

Maintenance – Keeping the man-machine-

material system in optimal condition.

The Aim is to prevent losses and achieve:

• Zero Accidents.

• Zero Defects.

• Zero Breakdowns.

Jishu Hozen means activities of the Production Team Member that uses

maintenance to personally conduct maintenance activities such as cleaning,

oiling, retightening and inspecting.

Jishu Hozen represents activities that eliminate equipment failures; minor stoppages; defects and losses by maintaining,

improving and restoring equipment to desirable forms.

The activities will prevent forced

deterioration of equipment, resulting in

increased production efficiency.

The Goal of Jishu Hozen is to develop operators to:

The Jishu Hozen is a step-by-step methodology for making the equipment

‘as it should be’.

Jishu Hozen has seven steps. The focus today is on Step 0 - 1, which is

‘conduct initial cleaning and inspection’.

Maintain equipment and work

places.

Follow uniformity in implementing shop floor

activities to eliminate forced deterioration on

equipment.

Become expert

equipment operators.

Jishu Hozen brings significant change to the “I Manufacture – You Repair” or

“I Make – You Fix” to “I Make – I Manage”.

Operators and Maintenance collaborate to ensure that the equipment is

completely healthy.

The Production Team Members must implement the following activities:

• Improvement of basic conditions of equipment such as Cleaning,

Lubricating, Retightening and Inspection.

• Adjustments such as adjustment in operation and setting up

prevention of quality defects.

• Prediction and early detection of abnormalities.

Forced deterioration is due to

abnormalities.

Force deterioration will occur if machines are not taken care of.

Production Team Members conduct activities to eliminate forced deterioration.

Work Together with Maintenance, eventually saving maintenance time to conduct

Planned Maintenance activities.

Grease hiding abnormalities

Recording maintenance

data to ensure feedback for prevention of recurrence.

Routine inspection on

the equipment.

Minor improvements

such as replacing parts

during abnormalities.

Speedy notification of

failures and malfunctions.

Assist in sporadic repair.

• Attention of the Team Member is diverted onto the equipment.

• 1S is Sorting the Workplace

• Tools that are kept around the equipment are classified into

necessary and unnecessary items. The sorting activity has to be

done by operators under the guidance of Supervisors or

Management.

• Decision Matrix for Sorting out Tools.

Priority

Frequency of

Use? How to Use?

Low Less than once

per Year.

Throw away.

Store away from

the workplace.

Average At least Once

per Month

Store together

but Off-line.

High Once per Day. Locate at the

Workplace.

Before and After Clearing area

The fundamental principle is

“Everything has place and everything in its place”

2S is Organising the Workplace

• Assign each Item with a label.

• Decide the right place for each necessary item, ensuring easy accessibility.

• Mark the locations.

• Draw a boundary around the

equipment/items to indicate its zone.

• Exhibit the status clearly e.g. “Tool Change”.

The Advantages of 1S and 2S are:

• Clean and efficient work place will be

created and shop floor housekeeping will

be of highest order.

• Movement of Team Member will be

minimized.

• Time spent searching for necessary items

are eliminated.

• Safer working conditions ensured.

• Increased productivity.

Form a cross-functional team comprising of shift operators, maintenance staff, office

staff and supervisors. All Team members need to know the meaning of

“Abnormalities”.

Initial cleaning materials required before commencing

with Step 1:

• White and Red tags, brushes, rags, cleaning

solvent, gloves, torchlight, cable ties and tool box.

All Team Members briefed on the Safety aspects of

equipment before cleaning.

Video and photographs captured before and after

initial cleaning. Management and workforce working together as a team, showing commitment to program

Audits are carried out to ensure the achievement of success of each step. Audits are carried out

in three stages by the:

• Team who had carried out the activity.

• Manager of the area.

• Unit head along with the TPM Secretariat.

The equipment should get at least 80 points during the Unit head audit. Thereafter, the next step

may commence.

The benefit is the operator is carrying out the

Important tasks and finding issues with the aim of

Bringing the equipment to “As New”