Autonomous Maintenance in Seven Steps : Implementing TPM on the Shop Floor

Autonomous maintenance is an especially important pillar of Total Productive Maintenance (TPM) because it enlists the intelligence and skills of the people who are most familiar with factory machines-- equipment operators. Operators learn the maintenance skills they need to know through a seven-step autonomous maintenance program. Most companies in the West stop after implementing the first few steps and never realize the full benefits of autonomous maintenance. This book contains comprehensive coverage of all seven steps--not just the first three or four.

It includes :

• An overview of autonomous maintenance features and checklists for step audits to certify team achievement at each AM step.
• TPM basics such as the six big losses, overall equipment effectiveness (OEE), causes of losses, and six major TPM activities.
• An implementation plan for TPM and five countermeasures for achieving zero breakdowns.
• Useful guidelines and case studies in applying AM to manual work such as assembly, inspection, and material handling.
• Integrates examples from Toyota, Asai Glass, Bridgestone, Hitachi, and other top companies.

By treating machines as partners and taking responsibility for them, you get machines that you can rely on and help maintain an energized and responsive workplace. For companies that are serious about taking autonomous maintenance beyond mere cleaning programs, this is an essential sourcebook and implementation support.

Preface
Introduction

Chapter 1 : TPM Aims at The Elimination of Losses

• 1.1 : The Shopfloor Suffers from Diverse Mistakes
• 1.2 : The Shopfloor is Flooded with Losses
• 1.3 : Understanding the Nature of Losses
• 1.4 : Why Losses Occur

Chapter 2 : A Summary of TPM

• 2.1 : Six Major TPM Activities
• 2.2 : The Effects and an Evaluation of TPM
• 2.3 : The TPM Master Plan
• 2.4 : The TPM Steering Organization

Chapter 3 : The Five Countermeasures to Achieve Zero Breakdowns

• 3.1 : The Basic Strategy to Attain Zero Breakdowns
• 3.2 : Who Takes the Five Countermeasures?
• 3.3 : Restructuring the Roles of the Production and Maintenance Departments
• 3.4 : Allocating Roles to the Production and Maintenance Departments

Chapter 4 : The Autonomous Maintenance Program

• 4.1 : The Aims of Autonomous Maintenance
• 4.2 : The Autonomous Maintenance Development Program
• 4.3 : The Step-by-Step Development of Autonomous Maintenance
• 4.4 : Work Procedures and Standards
• 4.5 : Educational Systems in Autonomous Maintenance
• 4.6 : Notes for Successful TPM Implementation
• 4.7 : The Twelve Keypoints of Autonomous Maintenance

Chapter 5 : Step 1 : Initial Cleaning

• 5.1 : Aims from the Equipment Perspective
• 5.2 : Aims from the Human Perspective
• 5.3 : How to Develop Step 1
• 5.4 : How to Proceed with Initial Cleaning
• 5.5 : Case Study
• 5.6 : The Keypoints of an Autonomous Maintenance Audit

Chapter 6 : Step 2 : Countermeasures to Sources of Contamination

• 6.1 : Aims from the Equipment Perspective
• 6.2 : Aims from the Human Perspective
• 6.3 : Time Targets for Cleaning and Tentative Standards
• 6.4 : How to Develop Step 2
• 6.5 : Case Study
• 6.6 : The Keypoints of an Autonomous Maintenance Audit

Chapter 7 : Step 3 : Cleaning and Lubricating Standards

• 7.1 : Aims from the Equipment Perspective
• 7.2 : Aims from the Human Perspective
• 7.3 : How to Develop Step 3
• 7.4 : Establish a Lubrication Control System
• 7.5 : Case Study
• 7.6 : The Keypoints of an Autonomous Maintenance Audit
• 7.7 : Review the First Stage of the Autonomous Maintenance Program

Chapter 8 : Step 4 : Overall Inspection

• 8.1 : Aims from the Equipment Perspective
• 8.2 : Aims from the Human Perspective
• 8.3 : The Necessity of Overall Inspection
• 8.4 : How to Develop an Overall Inspection
• 8.5 : Case Study
• 8.6 : The Keypoints of an Autonomous Maintenance Audit

Chapter 9 : Step 5 : Autonomous Maintenance Standards

• 9.1 : Aims from the Equipment Perspective
• 9.2 : Aims from the Human Perspective
• 9.3 : Finishing the Activities Relating to Equipment
• 9.4 : How to Develop Step 5
• 9.5 : Routine Inspection by Autonomous Maintenance
• 9.6 : Preparing Autonomous Maintenance Standards
• 9.7 : Case Study
• 9.8 : The Keypoints of an Autonomous Maintenance Audit

Chapter 10 : Step 6 : Process Quality Assurance

• 10.1 : Aims from the Equipment Perspective
• 10.2 : Aims from the Human Perspective
• 10.3 : The Challenge of Zero Defects
• 10.4 : A Prerequisite for Process Quality Assurance
• 10.5 : Step 6-1: Remedies Focused on Quality Results
• 10.6 : Step 6-2 : Remedies Focused on Quality Causes
• 10.7 : Step 6-3 : Establish Process Quality Assurance
• 10.8 : The Keypoints of an Autonomous Maintenance Audit

Chapter 11 : Step 7 : Autonomous Supervision

• 11.1 : TPM Fully Established on the Shopfloor
• 11.2 : Maintaining the Current TPM Level
• 11.3 : Aiming at a Higher Level of TPM

Chapter 12 : Autonomous Maintenance in Manual Work Departments

• 12.1 : The Basic Concepts of Autonomous Maintenance
• 12.2 : How to Develop Autonomous Maintenance
• 12.3 : How to Construct the Seven-Step Programs
• 12.4 : Autonomous Maintenance in the Assembly Department
• 12.5 : Autonomous Maintenance in the Inspection Department
• 12.6 : Autonomous Maintenance in the Material Handling Department

Glossary
Bibliography
Index