Prepared by TPM Secretariat, IIL, Dolvi 101

JISHU HOZEN

JISHU AUTONOMOUS / SELF PERFORMED

HOZEN MAINTENANCE

THE KEY WORD IS

“ITS MY MACHINE I MAINTAIN IT”

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 Introduction

Jishu Hozen, Japanese word for Autonomous Maintenance,

implies that the operators themselves maintain their machines in
highest standards. These operators are trained to do so through
the structured approach of 7 steps of Jishu Hozen. Each step has
a focus, an activity to be carried out and certain results to be
achieved.
This manual is written in a simple way to understand the 7 steps
of Jishu Hozen. Each step is explained in detail with flow charts,
pictures and successful case studies from different companies,
Audit sheet to check / monitor the excellent implementation of
each step is also included in this manual so that companies can
check for themselves where their implementation activities stand.

Prepared by TPM Secretariat, IIL, Dolvi 103

 Concept of Jishu Hozen
One of the special aspects of TPM is that the operators taking
care of the equipment from forced deterioration. This is made
possible by doing cleaning, lubrication, re-tightening and
inspection by themselves and trained through the step-by-step
procedure.

In this process, first, operators and maintenance persons come

together to improve equipment conditions. Second, it helps
operators to learn more about their equipment functions, common
problems that can occur and why and how these problems can be
prevented by the early detection. Third, this creates conducive
atmosphere for operators and maintenance staff to become active
partners in improving the overall performance and reliability of
equipment. The concept of "Jishu Hozen " is detailed out in this
manual.
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Concept of “ Jishu – Hozen”

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 Significance of "Jishu-Hozen"
Jishu-Hozen" means activities of the operator that uses maintenance to personally
conduct maintenance activities, including cleaning, oiling, retightening, and inspection,
thereby raising production efficiency to its limit. Such activities will prevent forced
deterioration of equipment. Thus "Jishu-Hozen" represents activities to thoroughly
eliminate failures, minor stoppages, defects, and other losses to restore equipment to their
desirable forms, maintain-them, and improve them, and at the same time to develop
"personnel that are skillful at equipment operations and improvement."

"Jishu-Hozen" is the operator's work itself. It is carried out under the step method through
small group activities closely unified with the managerial structure. It represents a major
characteristic of TPM.

TPM is designed to pursue production system efficiency to its limit through "corporate
structural improvement based on the constitutional improvement of personnel and
facilities," and “Jishu-Hozen" itself signifies the constitutional improvement of
personnel and facilities.
Efficiency will improve greatly, and the operator personally experiences the effect of
"Jishu-Hozen", so that his attitude will changed so as to protect his own equipment by
himself. Thus, in "Jishu-Hozen", the constitutional improvement of personnel an
equipment proceed simultaneously.

Jishu Hozen can be successfully implemented by first carrying out the 5S activities on
and around the equipment. Its only after implementation of 5S can the results of Jishu
Hozen can be seen and sustained. The concept of 5S is explained on the next page.
106
 “5S” – A Pre-requisite to achieve TPM
1S - Seiri (Sorting out): 2S - Seiton (Systematic Arrangement)
•Look around your work area and •Plan Storage with accessibility
ask your self “Is it really necessary
for all items to be there ?” •Use labels, colour codes, for easy
identification
•Segregate required, usable, rework
able and unwanted items.
•Dispose of unwanted items

3S - Seiso ( Shining)
•Inspect and clean work place,
machines, and Tools carefully
•Do regular inspection while
5S - Shitsuke (Self Discipline) cleaning
•Carry on 5S activities as a
matter of habit and enthuse
others to practice 5S
•Develop action plan for 4S - Seiketsu (Standardizing)
maintaining the set standards •Develop Standards
•Conduct Self-Audit •Create visual Controls
•Devise ways and means to
expose problems
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 This is what happens without Jishu-Hozen

Oil/ Air leakages Many Minor

from machines Tripping Due to poor Tanks overflowing
basic conditions

Poor machine
operating
condition &
reliability

Closed machine Difficult Searching for

No inspection Approach to Tools
in many cases Many machines 108
 What is the need of Jishu Hozen?

Usually, operator learns only method of operation and

maintenance person learns only about machine. When
problem arises with machine, operator calls maintenance.

Unfortunately, many process problems come from problems

in machines.

JH aims at making equipment

competent operator, who can
take care of his machine

Operators and the Maintenance

crew are two wheels of the
same vehicle

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 Aim of Jishu-Hozen
Developing Equipment Conscious Operator
Avoid Forced
Deterioration Avoid fouling of Make inspection/ Operation
On Equipments by equipment & maintenance
maintaining basic Due to any type of task easy by improving
conditions i.e. leakage/ Spillage Hard to access areas
Cleaning Lubrication on equipment & Establishing Visual Control
Tightening & Inspection

Towards Zero Breakdown

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SEVEN STEPS OF AUTONOMOUS
MAINTENANCE
STEP 1- INITIAL CLEAN UP

STEP 2 COUNTERMEASURES AGAINST CAUSES OF FORCED DETERIORATION

STEP 3 – PREPARATION OF TENTATIVE STANDARDS

STEP 4 – GENERAL INSPECTION

STEP 5 – AUTONOMOUS CHECK-UPS

STEP 6 - ORDERLINESS AND TIDINESS

STEP 7 – ALL OUT AUTONOMOUS MANAGEMENT

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 FOUR STEPS TO BECOME AN OPERATOR STRONG ON
EQUIPMENT AN AUTONOMOUS MAINTENANCE

AUTONOMOUS 4 STEPS TO
MAINTENANCE 7 BECOME OPR
STEPS STRONG ON EQPT

MASTER HOW TO REPAIR

STEP 7 – ALL OUT AUTONOMOUS MANAGEMENT THE EQUIPMENT

STEP 6 - ORDERLINESS AND TIDINESS

LEARN HOW TO OPERATE
THE EQUIPMENT WITH THE
REQUIRED ACCURCY AND HOW
STEP 5 – AUTONOMOUS CHECK-UPS TO EVALUATE THE PRODUCT QUALITY

STEP 4 – GENERAL INSPECTION

STUDY THE MECHANISM AND
FUNCTIONS OF SQUIPMENT
STEP 3 – PREPARATION OF TENTATIVE AND MACHINES
STANDARDS

STEP 2 COUNTERMEASURES AGAINST CAUSES

FAMILIARISE WITH THE CONCEPT
OF FORCED DETERIORATION
OF EQUIPMENT MAINTENANCE
AND IMPROVEMENT WITH
STEP 1- INITIAL CLEAN UP HOW TO PUT THE IDEA
INTO PRACTICAL REALIZATION
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 Audit Procedure for JH Step Clearance
Audits are the most important activity that ensures the achievement of success of each
and every step. This is done at the end of each step. Audit is carried out in 3 stages.
First by the team which has carried out the activity, second by the manager of that area
and third by Divisional Head along with the TPM Secretariat. This approach ensures that
the results achieved in a particular step of Jishu Hozen are sustained for a long time and
there are no slippage.

When the team conducts the audit they should achieve a score of atleast 90 points
before they request for managers audit. If the score of 90 points is not reached, the team
has to study the equipment again and repeat that step activities till they reach or cross
the score. Only after this they can request for managers audit . During the managers
audits the score should be atleast 85 points to request for Divisional Head’s audit. The
Divisional Heads audit starts after the equipment has 85 points or more. For clearing the
step the equipment should get atleast 80 points during the Divisional Head’s audit. After
this the next step is taken for implementation.

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 BM and Targets for Jishu Hozen – An Example

S Parameter Unit 2001- 2002-03 2003-04 2004-05 Better Responsibility

No 02
Bench Actual Actual Actual Target Primar Secondar
Mark y y
1 Production No of 14 19 24.9 30.5 36 KK JH & PM
Rate heats /
day

HR coil 865663 1247038 1619170 160973 2213785 KK JH & PM

Prodn / 4
FY

2 JH Kaizen Cum. No 15 286 710 1500 1910 JH PM

3 OPL’s Cum. No 0 220 734 1407 1454 JH PM & ET

4 Visual Cum. No 21 80 888 1884 2016 JH PM

Controls
5 Good to Cum. No 0 0 12 32 50 JH PM & ET
find
6 Lack of Minutes NA NA NA 1131 Yet to JH ET
skill (Delay (past be
six analysed
month) and set
7 Miss Minutes NA NA NA 958 Yet to JH ET & PM
operation (Delay) (past be
six analysed
Prepared by TPM Secretariat, IIL, Dolvi
month) and set 114
 Jishu Hozen Master Plan – An Example
SMS Caster
2002 2003 2004 2003 20
Pillars

ets
rg
Ta Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2

A Rank
Jishu Hozen Step 0 B Rank
C Rank
A Rank
Jishu Hozen Step 1 B Rank
C Rank
Jishu - Hozen

A Rank
Jishu Hozen Step 2 B Rank
C Rank
A Rank
Jishu Hozen Step 3 B Rank
C Rank
A Rank
Jishu Hozen Step 4
B Rank
A Rank
Jishu Hozen Step 5
B Rank

Start Finish Sustain

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Format for TPM Activity Board for Equipments
From JH step 1 to 3
1.MODEL 2.Jishu Hozen 3.TEAM- 4.Master plan 5.Route map 6.Pre Tentative
MACHINE LAYOUT Pillar Leader- upto step 3 Standard
(what's pillar) Members-
JISHU HOZEN
STEP in progress-

Pictorial layout .Use your innovation to Graphical - Route map Time taken
&location of m/c depict team plan v/s actual denotes team work,planning beforeJishu Hozen for
.photograph of team and accountability cleaning,
members may also be used lubrication and
inspection

12.Kaizens 11.OPL 10.Classification 9.Cumulative 8.Individual time 7.Time graph

One Point Leeson of Fuguai graph of Fuguai identified graph (Cumulative graph of
(6 categories) v/s rectified (cumulative graph of planned v/s actual
planned hours v/s actual hours)
hours)

.Cumulative Graph .Cumulative Graph % fuguai in .monthwise Memberwise updated monthly

Target v/s Actual Target v/s Actual each category .updated every month time spent
.copies of Kaizens .copies of OPL'S

. .

13.AUDIT SHEET 14.GAINS 15. List of Hard to Access 16. List of Sources of 17.GOOD TO FIND
Self Audit as well as third level Quantify gains tangible & Area & provided dust, dirt & contamination CORNER
audit intangible countermeasures & provided (Before & After
countermeasures Photographs)

116
 STEP -0

1. Importance and benefits of JH(I maintain my machine) to operators

2. Operators role in JH activity must be communicated in the awareness training
programme itself.
3. Basic Construction of Machine, its schematic diagram & parts.
4. Awareness on Basic Equipment Condition
5. What is the meaning of ‘abnormality’? – dirty, loose, hanging,
leaking,splashing/spilling, broken, hardened, excess length/heat,
vibration,corrosion, crushed, unwanted, missing, bent, holes, worn-out,abnormal
noise, discoloration,
6. Safety Aspects of the machine
and clothes to wear while
carrying out JH Activity

7. Difference between Forced &

Natural Deterioration as seen
for their own equipment

8. Explain Blue and Yellow tags

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 Preparation (Step 0)

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 STEP 1 – Perform Initial Cleaning

The purpose of Step 1 is to understand the relationship between

equipment defects and forced detoriation and to master the
concept of “Cleaning is Inspection” and bring the equipment
back to its basic condition
1. Cleaning FOR inspection
2. Use 5 Senses for inspection
3. Find out 6 types of abnormalities
4. Put tags on abnormalities
5. Take corrective actions against the identified
abnormality
6. Prepare list of unfulfilled basic conditions
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STEP 1 – Perform Initial Cleaning

120
Procedure to Implement Step 1

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 Cleaning FOR Inspection

Why Cleaning is Required?

• Cleaning is Inspection.
• When you clean, you
develop a new eyesight, of
seeing what is invisible.
• While looking, the nut-bolt
appears ok, but when you
touch it, you realize it is
loose.
• Early detection allows
early correction, which
prevents it from becoming
a big fault.
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 What to Look For, While Cleaning?

IN STOPPED and ELECTRICALLY ISOLATED MACHINE

1. Very Dirty Areas

2. Un-lubricated Areas
3. Loose fasteners/ belts/ electrical connections
4. Play
5. Out of alignment
6. Out of straightness
7. Signs of wear and tear
8. Inaccessible or difficult to clean areas
9. Difficult to inspect areas
10. Can cause frequent breakdowns
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IN STOPPED and ELECTRICALLY ISOLATED MACHINE – Contd….

11. Can cause unsafe conditions

12. Can cause quality problems
13. Parts and accessories not in use but still attached to
machine
14. Gauges and instruments which are non-functional/ not
calibrated
15. Contaminated fluids, lubricants
16. Missing or choked filters
17. Corrosion
18. Deformation
19. Dents on machined surfaces
20. Imperfections
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What to Look For, While Cleaning?
IN RUNNING AND ELECTRICALLY ISOLATED MACHINE

1. Vibrations
2. Leakages of oils, lubricants, air, steam, water
3. Unusual noise
4. Working of cooling fans
5. Unusual smells
6. Wobbly movements
7. Eccentricity
8. Malfunctioning gauges
9. Function of safety devices
10. Function of error proofing devices
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 What to Look For, While Cleaning?

11. Function of proximity and limit switches

12. Function of sensors

13. Measure things like current drawn by motor, it’s

insulation resistance

14. Speeds and feeds

15. Temperature, pressure and other process

parameters against standards

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 When to do it?`

• Cleaning is NOT one-time activity.

• Cleaning has to be done according to a
schedule.
• Production Planning must keep time
aside for Initial Cleaning.
• Ideally, keep 2 to 3 hours a week.

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 Initial Cleaning – How to do?

• Form teams, primarily of those operating the

machine. In the Preparatory Phase, the
management teams do it themselves.
• At the time scheduled for Initial Cleaning, the
team cleans the machine and surroundings
for (say) one hour..
• While cleaning, identify abnormalities. If you
have 2 hours, spend 1 hour to clean and 1
hour for:
– Putting Tags
– Removing Tags
– Generating “One Point Lessons” and
– Updating the Autonomous Maintenance Board
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 Types of Fuguais (Abnormality)

Inaccessible area
Forced Deterioration
Not able to fulfill the specified requirements
Not user friendly
Items not kept at designated places
Unsafe condition

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 TYPES OF FUGUAI TAGS

BLUE TAG YELLOW TAG

CORRECTED BY THE

TO BE FILLED IN AND
CORRECTED BY THE
TO BE FILLED IN BY THE

SUPPORT/ MAINT. DEPT.

OPERATORS AND TO BE

OPERATORS THEM SELVES

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 Initial Cleaning – Tagging

• For every abnormality, create a TAG.

• Use Blue tag as far as possible. Blue means, you
take the responsibility to correct the abnormality.
• If you must take help to do it, then put YellowTag.
• Make each tag in duplicate – put copy on machine.
• Write the tags on the TAG LIST and then give green
tag original copy to or Shift Manager, and Yellow Tag
original to Maintenance.
• Classify the tags - simplest classification is:
– High Priority - do it in three days
– Low priority & easy to do - do it within a week
– Low priority and & to do - this can be pending.

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DETAILS TO BE ENTERED IN A FUGUAI TAG

Please enter the Fuguai

Number based on your records
in the fuguai Register

Please enter the Name of the

Equipment / area where the
fuguai has been observed

Please enter the details of

Fuguai that has been observed

Please enter the date on which the

Fuguai has been detected

Please enter the name of the person

who has detected the fuguai

Please enter the job done to

Counterfoil

rectify the fuguai

Please enter the date when the

fuguai has been rectified and
by whom the fuguai has been
attended by
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 Removing Tags

•After putting tags and making tag list, start

removing tags by correcting the abnormality.
•Take at least temporary countermeasure on the spot,
rather than wait for the perfection.
•Attack tags according to priority set.
•Assign responsibility for tag removal.
•Go for perfection, but don’t wait for it.
•Try to put more Blue tags – it will enhance your
skills and capabilities by providing more
opportunities to remove tags by yourself.

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 The details in this
register
shall be based on
Please Please enter the the
enter the details of the data as entered in
serial no. fuguai as the fuguai tag
of the entered in the
fuguai fuguai tag

THERE ARE 6 TYPES OF FUGUAIS AND ALL THE FUGUAIS ARE TO BE CLASSIFIED IN
THIS CATEGORY

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STATUS INDICATOR SHOWS THE PROGRESS
OF JH ON MACHINE

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KAIZEN TAG TO BE DISPLAY WHERE
KAIZEN HAS BEEN DONE

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 One Point Lessons:

One point lessons are developed to increase basic knowledge and

skill improvement to reduce breakdowns and defect due to poor
knowledge and skills.
a. Relating to equipment abnormalities, safety, breakdown and
Quality detected during trouble-shooting
b. Machine leaders, maintenance staff, quality staff to prepare
c. Team leader to teach
d. Highly visual.
e. Relating to repeated mistakes or can mistake areas which lead to
Customer Complaints / BDs

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One Point Prepared by: ……….. Approved by ……….
Lesson Prepared on: ………… Administered by …….

Type: Basic Knowledge/ Problem Prevention / Improvement Sustenance

Wrong Correct

Photo/sketch Photo/sketch

Training Person: ABC DRC PMR

Record Sign:
Date: 14.5.01
Prepared by TPM Secretariat, IIL, Dolvi 141
 ONE POINT LESSON – An Example
Lesson Number : TPM/OTPM/Sec 01
Division : Security
Theme : FILE KEEPING

BASIC KNOWLEDGE TROUBLE SHOOTING IMPROVEMENT CASES

Improper Filing Proper Filing

X a
PREPARED BY : Capt. V. Nair DATE: 13 Dec02 CHECKED BY: Lt. Col.C. M. Chavan

TRAINING DATE 15.12.02 16.12.02 18.12.02

TRAINING IMPARTED BY CBS SSD SB

TRAINING IMPARTED TO Nitin Patil Ganesh K T Kothekar

Prepared by TPM Secretariat, IIL, Dolvi 142

 What is FORCED DETERIORATION?

Natural Deterioration
Equipment Condition

Forced Deterioration

Time

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Find places with dirt stains,dust and foreign matter
accumulated

Analyze dirt , dust and material

Analysis of generating sources

Do they generate in a prior process

Are they generated by machining

Are they generated by equipment

Do they come from the outside plant

Device countermeasure

Eliminating generating sources

Schedule.operators in charge and plan

KAIZEN 144
145
Step-2:Measures against sources of problems
and difficult areas

Understand evils of dirt,stains,dust and foreign matter

To eliminate sources generating dirt,dust and stains
To improve places that are hard to access for cleaning,
lubrication,inspection and retightening
To improve places where leakage and material spillage

Prepared by TPM Secretariat, IIL, Dolvi 146

Step-2:Measures against sources of problems
and difficult areas
 Benefits of JH Step-2

Make the equipment easier to clean

Minimize the spread of dirt,dust & oil
Stop contamination at its source
Minimize the scattering of cutting oil and chips
Speed up the flow of cutting oil to prevent accumulation
of chips
Make the equipment easier to inspect
Simplify wiring and piping layouts
Make it easier to replace equipment parts

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149
Step-3 –Develop tentative standard for Cleaning,Inspection
and Lubrication

Basic conditions of activities to prevent equipment

detoriation
Maintenance and management of cleaning ,Lubrication
and Inspection
Action standard allowing accurate maintenance of basic
conditions quickly is prepared by oneself
New ideas for visual control

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 Step-3: Preparation of Tentative Jishu-Hozen Standards
• Maintenance and control of Cleaning, Lubrication Inspection and Tightening, which are basic
conditions for activities to prevent equipment deterioration
• Preparing action standards that allow basic conditions to be put in place without fail in a short period
• Devising the method for Visual Control

Cleaning/ Inspection/Tightening
( In Step 1 and 2)
•Clarification of location Lubrication
Lubrication
Minor defect
•Clarification of methods •Clarification of members, lubrication manuals
detection list
types, volume ,tools ,frequency
•Clarification of standards
Improvement •Exposure of minor defects during Lubrication
records •Clarification of measures to fix oiling training
abnormalities
Confirmation of •Improvement
the target time •Clarification of frequency
•Target time-setting
•Target time-setting

Preparation of Standards Study of the hazards of conventional

Utilization of standards and the reason the
visual control Implementation of Cleaning /Lubrication /Inspection standards could not be observed

Corrective Variance from the target time

action
Improvement Improvement records

Confirmation of execution Details of activities

Circle activity report/ plant

Self audit
diagnosis application
Departmental audit

Approved(Third
151
level audit)
 T e n t a t iv e s t a n d a r d - M o n t h - J u ly ' 0 4
A r e a - S M S U ti l i ty E q u ip m e n t n a m e - P u m p T e a m L e a d e r - M r.
Sample

Fre q u e n cy A c ti o n i n Date 1 2 3 4
Sr. P ar am e te r to R e s p o n s ib
Part Nam e S ta n da r d M e th o d T o o ls cas e of T im e
no be che ck e d W e e k l Fo r tn i M o n th ilit y
D a ily (s e cs )
y g h t ly ly a bn o r m a l i ty
No

In f o r m
Sound abn o rm al Hear 10
m a in t e n a n c e
n o ise

Pu m p In f o r m
1 T e m p e r a tu r e < 60 deg C Feel 10
b e a r in g D E m a in t e n a n c e

No In f o r m
V ib r a t io n Feel 10
V ib r a t io n m a in t e n a n c e
No

In f o r m
Sound abn o rm al Hear 10
m a in t e n a n c e
n o ise

Pu m p In f o r m
2 T e m p e r a tu r e < 60 deg C Feel 10
b e a r in g N D E m a in t e n a n c e

No In f o r m
V ib r a t io n Feel 10
V ib r a t io n m a in t e n a n c e


Mech seal In f o r m
3 L e a ka g e N o le a k a g e V is u a l 15
DE m a in t e n a n c e


Mech seal In f o r m
4 L e a ka g e N o le a k a g e V is u a l 15
NDE m a in t e n a n c e


Pre s s u re In d ic a t o r in In f o r m
5 Pre s s u re V is u a l 15
gauge G reen z one m a in t e n a n c e


In f o r m
6 V a lv e s W o r k in g W o r k in g V is u a l 30
m a in t e n a n c e


In f o r m
7 F la n g e s L e a ka g e N o le a k a g e V is u a l 30
m a in t e n a n c e
B e tw e e n F ill g r e a s e


G reas e
8
cups
Level m in & m a x V is u a l u p to m a x . 15 152
le v e l le v e l
153
 STEP-4 – General Inspection
From step 1 to 3 the focus points are “elimination of forced
deterioration and “set up basic conditions". Through these points
,grasp malfunctions ,take counter measures against the source, and
establish cleaning and inspection tentative standard .In these steps
,you can recognize malfunction as malfunction and understand how
to do equipment improvement .
Up until here ,your five senses mainly spot the malfunctions.
However ,take one more step further to understand the function and
the structures of your machine deeply ,and it is the main target of
this step that you should establish the daily check-up system based
on knowledge and reasoning of the machines .

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 STEP-4 – General Inspection

Note that when you do check-ups,you should prioritize to

find out chronic loss that leads malfunctions (failures and
defects ),and to take appropriate countermeasures.
To achieve the target, deterioration measurement skill is
required to predict the defects /the failures through
general inspection.

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 Step 4 of Jishu Hozen : General Inspection
General Inspection Implementation
1. Bolts and nuts Prepare one point lessons
2. Lubrication
Training 3. Hydraulics
4. Pneumatics
5. Drive System Transmission of education
6. Electric
Analysis of 7. Safety
General Inspection Manual
results 8. Machining Conditions

Inspection Comprehensive check

Skill Check

Restore & Improve

Self audit for each Activity Report

Items pointed
Out (Fuguai Observed) subject

Application for
Machine audit
Purposes of Step 4 :
(1) Understand structures, functions, principles and proper approach of equipment.
(2) Learn skills to inspect principal functions and parts comprising equipment.
(3) Thoroughly inspect principal functional parts comprising equipment and actualise Passed
and fix latent defects. 156
Procedure for Implementing Step4

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 Step 5: Autonomous inspection
It is necessary to maintain and improve the equipment deterioration
rectified state that has been achieved in the previous step(step1to4) and
further improve the reliability ,maintainability and quality of equipment.
For this purpose ,this step is intended to review cleaning ,lubrication and
inspection standards ,improve inspection efficiency ,achieve the state
free from inspection error ,and establish the autonomous standard.

Activity :

1.Integrate the tentative standard of step 3 (C, L, I, T) with

comprehensive routine inspection to contribute to efficiency of the
activity.
2.Prepare and implement autonomous inspection check sheets.
3.Raise operational reliability by training operators about process,
operation and maintenance.

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Autonomous Inspection (Step-5)
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 Step 6: Standardization
In the previous steps, you have taken activities concentrating
on the fulfillment of the basic conditions and daily inspections
of equipment itself. This step is intended to reliably maintain
and control those activities and extend operators' roles to
related work in the peripheral of the equipment to further
reduce losses and complete the autonomous maintenance .

Activity:

Implement standards and visual checks of the equipment,

spares, tools, materials in process, products, data and
surrounding area etc at work place.

Prepared by TPM Secretariat, IIL, Dolvi 166

Step 6:Standardization
Prepared by TPM Secretariat, IIL, Dolvi 168
Step 7: Thorough implementation of autonomous
management
This step is a place where you summarize all the activities taken
in Step1 to 6 and you get confidence in producing effects by
changing equipment, man and workshop. Based on the concept of
“improvement is infinite”, you will continue challenge and be
impressed with participation cooperation and creation.

This step is also intended to make individual workers to act like a

self-contained electric car rather than an electric locomotive ,and
be capable of carrying out corporate policy and subjects .
Purpose:
• Establish an autonomous management system to keep on challenging
based on the activities that have produced effects by changing
equipment and man.
• Strive for zero failures and zero defects and positively participate in
upstream control.

Activity:
1.Prolong equipment life and inspection intervals by performing
improvements after determining equipment weakness.
2. Promote high awareness of management using targets and impart
strong cost awareness that includes maintenance costs .
3. Raise process reliability, safety, maintenance, quality and operability
by making improvements based on analysis of data.
4.Train operators in repair and restoration techniques.
Prepared by TPM Secretariat, IIL, Dolvi 170
Prepared by TPM Secretariat, IIL, Dolvi 171