JIPM-TPM.Sample-Forms-Editing-2

aning Area Map of Cleaning Area

_________________ Section __________________ Department

Area Person-in-charge Remarks

7•2

5-3

© JIPM

Created: __/__/__ Cleaning P
Machine name:
Illustration __________________ Circle _____

No. Part Sta

Cleaning points (illustration or photo) (3)
(1) (2)

Procedure Cleaning Procedure

______________ Section __________________ Department 7•2
andard Method Tool Person-in-charge Time
5-4
(4) (5)

© JIPM

Map of Oilin

__________________ Circle _____

Model: __
General view

Oiling points (illustration or photo) (3)
(1) (2)

ng Locations Map of Oiling Locations

______________ Section __________________ Department 7•2
Machine No. __
5-5
(4)

© JIPM

Map of Retighte

__________________ Circle ________

Model: __
General view

Retightening locations (illustration or photo) (3)
(1) (2)

ening Locations Map of Retightening Locations

___________ Section __________________ Department
Machine No. __

(4) 7•2

© JIPM 5-6

Example of Tags and Usage 7•2 5-7

Example of Tags and Usage

Red tags and white tags Case for inserting tags

Usage method Usage method

In autonomous maintenance steps 1-5, the operator inspects Use the tag case when attaching tags outside or at locations

his/her own equipment and attaches tags to locations where where water or oil may splash. The bottom of the case has a

problems were discovered. A white tag is used for locations resealable closure, making it easy to insert and remove tags as

where repairs can be made on one's own and a red tag is used well as to reuse the case.

when it is necessary to request repairs to specialized

maintenance staff. Since the tags are in duplicate, tear off

one copy after recording the details and keep it as one's own

copy.

Example of usage

© JIPM

Planning Chart for Im

Machine name: ____
Counterme
Part No. Details of minor
defect P

Illustration or photo

mproving Slight Defects Planning Chart for Improving
Slight Defects
_______________ Section ________________ Department

easure Schedule (month) Comple
tion
Person-in-
charge

7•2

5-8

© JIPM

Classification Table o

Machine name:

Details of minor Identification Improvements and
defect countermeasures

Identifi- : Can be processed Month/ Identi- : Handled in the circle Sched- Comp
cation day fied uled tion d
Part symbol during operation by : Make request to
: Processed during comple-
maintenance staff tion date

change-over : Make request to

: Processed when engineering staff

the line is stopped Person-in- Details
charge

of Identified Slight Defects Classification Table of Identified Slight Defects

__________________ Section __________________ Department

Relationship to Area Improve-
ment sheet
7 major losses

ple- Improvement Failure Cutting Set-up Start- Minor Speed Defect Gener Difficult- Difficult Issu- Person
date results losses and
losses blade and up stop- rework ating to- -to- ance -in-
ing
re- adjust- losses page losses source access access No. charge

place- ment losses cleaning oiling

ment losses location location
losses

7•2

5-9

© JIPM

Know-Why Sheet 7•2 5 - 10

Registration No. __

Know-Why Sheet

Case name Identified by

Circle Date Created Section Subsection Circle
name created by Manager Manager Leader

__/__/__ What will happen if left as is?
What kind of defect is it?

Why did this occur? What countermeasures will you take?

Circulate

Horizontal
replication Verifica-

tion seal

Record __/__
of

education

Name

© JIPM

Table of Identified Difficult-to-Access Loca

Machine name: __
Co
Area Oiling Description of Reason for Descr
No. Cleaning Inspection difficulty difficulty

ations for Cleaning, Inspection and Oiling Table of Identified Difficult-to-Access Locations
for Cleaning, Inspection and Oiling
_________________ Section __________________ Department

ountermeasures When will it be
done by (month)?

ription Person-in- Month Month Month Month Month Month
charge

7•2

5 - 11

© JIPM

Improvement Sheet 7•2 5 - 12

Improvement Sheet

1. Autonomous maintenance No.
2. Individual improvement Created: __/__/__
3. Quality maintenance
4. Other

Case name

Purpose of improvement

Target machine ________________ Subsection ________________ Section Machine No. __

Suggested by __/__/__ Estimated expenses

Scheduled Scheduled to be
implementation date implemented by

Completion date __/__/__ Implemented by

(Before improvement) (Illustration)

(After improvement) (Illustration)

(Effectiveness, and policies after improvement)

© JIPM

Improvement Location Seal 7•2 5 - 13

Improvement Location Seal

Improvement location seal
(Top: Large; Bottom: Small)

Usage example

© JIPM

Tag Removal Tree 7•2 5 - 14

Tag Removal Tree

Actual example

© JIPM

Autonomous Maintenance Ste

Circle Section

Time
period

__/__

ep 1: Changes in Activity Time __/__ Improvement Effectiveness

Department

© JIPM 7 • 2 5 - 15 - (1)

Autonomous Maintenance Step 1: Changes

Circle Section

__/__

s in the Number of Tags Attached Improvement Effectiveness

Department __/__

© JIPM 7 • 2 5 - 15 - (2)

Autonomous Maintenance Step
Know-Why Sh

Circle Section

__/__

p 1: Changes in the Number of __/__ Improvement Effectiveness
heets Issued

Department

© JIPM 7 • 2 5 - 15 - (3)

Step 1 Diagnosis Sheet 7•2 5 - 16

Subsection Section TPM autonomous maintenance Step 1
Target equipment: Department Initial cleaning diagnosis sheet

Diagnosis points and items cited Evaluation points

Viewpoint Look, touch, listen, smell

Is cleaning Breakage, Are there any Not oiled Are difficult- Are problems Problems Problems not Problems Not
attempting to
being done wear, defects in the Inadequate to-access uncovered exhaustively yet continue to find problems

so that things deformation, positioning or oiling Amount cleaning and and uncovered completely arise 0

can be defects, play attachment of of oiling oiling countermeas but counter- uncovered 0

inspected? and dirtying parts or unknown locations ures measures not 0

Chemicals, of parts loosening of Not visible made completed? yet
tangible?
waste, dust, nuts and No level completed
bolts? indicator
rust, mist,

paper scraps,

scales, glass

shards, metal

scraps

Area 7532

The machine
surroundings are:
Floor, wall, pillar,
inside a pit,
curtain, ceiling

Have you 64

exhaustively

uncoveredpr

oblem points

from a The machine 9742
8 63
functional exterior is:
viewpoint?Ha Frame, piping,
ve you
wiring, etc.
corrected

those that

can be dealt

with?

The machine 15 11 5 2
interior is:

Mechanical,
optical, sensors

13 7 3

Peripheral 86420
equipment 75
includes:

Spare parts, 64210
consumables, jigs
and tools,
measuring
instruments

Control panel, 74210
electrical system, 63
motor, pump
__/52 Points
(Comments)

Diagnosis date: __/__/__ General inspection Pass 80 points or more
Diagnosed by __/100 points
Try again

Item Guidance items Evaluation level and evaluation points

o Are the sources that generate dirt, Understands Understands for Only half Does not Has almost no
s leakage (oil, chemicals and air), completely and the most part understands understand understanding
keeps records many parts
waste, and dust understood? 0
543 2
Are counter- Has almost no
understanding
measures
0
being taken for

the generating Are the amounts of leakage Understands Understands for Only half Does not
sources of (supplemental amounts) and falling completely and the most part understands understand
waste, dirt, dust understood? keeps records many parts
rust and
432 1
leakage?

Taking Fundamental Temporary Partial measures Created plan for Almost no work
measures on measures are measures are
Are efforts one's own completed completed are completed counter- done at all
being made to
take counter- Requesting 5 4 measures
measures for others
generating 320
sources?
Plan for counter- Drafting of plan Separated items Almost no work
to be requested done at all
measures is together with to others

clear others in 10

progress

32

Are counter- •Are measures Taking Completed Completed Gathering ideas Isn't coming up In a disposition
measures being taken to measures on counter- partial counter- with good ideas to give up
being take to prevent one's own measures with measures
prevent splashing of good ideas 210
splashing chemicals, Requesting 3
and to mist, oil and others 4
prevent the water?
introduction •Are measures Plan for counter- Drafting of plan Separated items Almost no work
of waste? being devised to be requested done at all
for materials, measures is together with to others
attire, writing
implements clear others in
and paper?
progress

32 10

(Comments) __/ 24 points

Evaluation standard Visually Created a report Data collection in Discussions Not started at all
understood
progress have started
5
What is the Item 4320
status of 5
visual (1) Are the number of problem points understood and 4320
autonomous their relationship to the 7 major losses 5
maintenance understood?
activities?
(2) Is the effectiveness of autonomous maintenance
grasped in a visual form (failure losses, minor 4320
stoppage losses, speed losses, and set-up and
adjustment losses)

(3) Are review meetings held and do all members
understand the problem points of that day?

(4) Are suggestions for improvements being made? 4 3 2 1 0

(5) Are future methods to advance the process 5 4 3 2 0
systematic?

(Motivating slogans and future autonomous

maintenance plan)

(Comments) __/ 24 points

© JIPM

Procedure for Implementing Step 2 7•2 6-1

Procedure for Implementing Step 2

* Step 2 eliminates the "sources" of forced deterioration, and implements mechanisms that
keep this activity to a short period of time.

Preparation of 1. Obtaining consensus of activity, dividing roles, and sharing of goals and purposes

countermea- 2. Scheduling of activities (in monthly, weekly and daily units)
sures for 3. Taking pictures of the actual situation before cleaning
generating 4. Preparation of materials and tools for improvement (cardboard, gum tape, etc.)
sources and 5. Preparation of tags, list of generating sources and difficult-to-access locations, etc.
difficult-to- 6. One-point lessons on "What are generating sources and difficult-to-access locations?" and "What are the
access
locations physical latent defects of management key points?" (Use this textbook)
7. Training of skills on "Making things"

8. Implementation of one-point lessons on the structure and functions of equipment from the viewpoint of

management key points.

9. Observation of a pilot organization model machine: Understanding the approach to improvement

10. Sharing of "improvement as it should be": Recognizing expense vs. effect

Implementa- 1. First carry out safety measures
tion of 2. Identification of generating sources and difficult-to-access locations: Ongoing since Step 1
countermea- 3. Identification of physically latent defects of management key points (difficult-to-manage functions)
sures for 4. Countermeasures for generating sources and difficult-to-access locations: Don't terminate countermeasures
generating
sources and in the first phase of improvement!
difficult-to- 5. Create the foundation for visual management of management key points (make visible the countermeasures
access
locations for physically latent defects with respect to functional parts) --> "make transparent" and "make visible"
6. Implement "countermeasures for splashing": Start with a "cardboard strategy"!

Stop → Enclose → Receive → Collect → Make easy to process → Visible
7. Compare the standard for passing Step 2 with the current level (make activity issues tangible)

Measurement 1. Effect before and after improvement: "Quantitative measurement" (the calculation standard is important)

of effects 2. Check variance of improvement cost vs. effect (evaluation results)

3. Take a photo after improvement: Take successive photos of each stage of improvement

4. Understanding the number of cleaning, inspection and oiling locations, and the required times and periods

5. Understanding the number of equipment management locations of management key points, and the required
times and periods

6. Comparison of the standard for passing Step 2 with the current level (make activity issues tangible)

Circle 1. Understanding the number of generating sources and difficult-to-access locations, and the details thereof
meetings 2. Investigation of countermeasures and methods for generating sources and difficult-to-access locations:

Analysis of causes is important! (Share the results)

3. Creating an example of taking a photo after improvement (know-how through a one-point lesson)
4. Consider making requests to other departments for improvements: Let's make improvements together!
5. Suggestions for ideas to visualize physically latent defects (locations with difficult-to-manage functions)
6. Determination of next activity schedule, activity details and things to prepare
7. Creation of an activity report and recording the results on the activity board

Preventing 1. Creation of tentative cleaning and inspection standards (standards evolved since the Step 1 tentative

future standards)

reoccurrence 2. Training of behavior based on the tentative cleaning and inspection standards

3. Implementation of "visual schemes" for improvement locations ("Beige" strategy, etc.)

4. Step 3: Things needing further improvement

5. Implementation of autonomous maintenance: On an equipment unit and circle unit basis

6. Implementation of a tentative step diagnosis: On an equipment unit basis

7. Implementation of the final step diagnosis: On a circle unit basis

Proceed to Step 3 Tentative diagnosis of all equipment
Final diagnosis on a circle unit basis
Advance after passing the diagnosis

© JIPM

Planning Chart for

Purpose

Date

Activity item

1 Clarification of generating sources and difficult-
to-access locations

2 Drafting of countermeasures

3 Restoration and improvement

4 Verification of improvement results

5 Autonomous diagnosis

6 Top executive diagnosis

r Step 2 Activities Planning Chart for Step 2 Activities

Circle Section Department

7•2

6-2

© JIPM

Map of Genera

Dirt Oil leakage Countermeasurescompleted
Air leakage Water leakage

Illustration

Lifter Degreaser Degreaser

No. Part Details No. Part D
1 Loader Oil leakage in bearing 6 Degreaser vat Dirt due
No. 1 leakage
2 Loader Oil leakage in bearing 7 Degreaser vat Dirt due
No. 1 leakage
3 Lifter Air leakage in air 8 Passageway Dirt due
cylinder unit leakage
4 Dryer unit Air leakage in air 9 Degreaser vat Leakage
knife pipe joint No. 2
5 Conveyor Sprang from Leakage
degreaser vat 10 High pressure from the
rinser No. 1

ating Sources Section Department Map of Generating Sources
(What, Where and How Much)
Circle

High Chemical rinse High Dryer
pressure pressure
rinser rinser

Details No. Part Details 7•2
to fluid 11 Sink Water leakage from
the piping joint
to fluid
6-3
to water
from the sink
e of coolant

e of water
packing unit

© JIPM

Map of Difficult-to-Access Cleaning

Circle Subsection

Department Machine name: __ No. __

Cleaning Oiling Inspection Countermeasurescomplet

Illustration

Lifter Degreaser Degreaser

No. Part Details No. Part D

1 Lifter Cleaner does not fit 6 Chemical rinser Same as

underneath lifter

2 Conveyor Cannot clean 7 Loader bearing Difficult t
because
because of cover
8 Loader bearing is on the
3 Degreaser tank

No. 1 Cannot clean

4 Degreaser tank because cleaning 9 Loader shaft Difficul
inside d
No. 2 tools do not fit 10 Degreaser tank
No. 1 operati
5 High pressure under the tank inspect
danger
rinser No. 1

g, Inspection and Oiling Locations Map of Difficult-to-Access Locations
(What, Where and How Much)
Section

ted

High Chemical rinser High Dryer
pressure pressure
rinser rinser

Details No. Part Details
s Nos. 3-5 Same as Nos. 9-10
11 Degreaser vat
to lubricate No. 2
e grease inlet
e inside 7•2

lt to see 6-4
during
ion; cannot
t because it is
rous

© JIPM

Why-Why An

Why-Why Analysis Sheet Circle Section
Why
Date created: __/__/__ Description of anal
Phenomenon

Why Why

nalysis Sheet Why-Why Analysis Sheet

Section Subsection Circle Created
Manager Manager Leader by

Department

lysis Improvement points
Why
Why

7•2

6-5

© JIPM

Planning Chart for Generating Sources Counterme

Map Leakage Dirt Generating source Details Details P
of
No. Air Oil Water Process Post Ma- Equip- Brought W
itself process chining ment in counter- th
related measures

easures, Improvements and Restoration Schedule of Generating Source Counter-
measures, Improvements and Restoration
Circle Section

Machine name:

Person-in-charge Classification Schedule

Within Engi- Sup- Elimi- Reduc- Range Local Month Month Month Month Month Month Com-

he sec- neer- plier nation tion __ __ __ __ __ __ pletion

tion ing

7•2

6-6

© JIPM

Example of Countermeasures for Difficult-to- 7•2 6-7
Access Cleaning and Inspection Locations

Improvement Sheet

1. Autonomous maintenance No.

2. Individual improvement

3. Quality maintenance Created: __/__/__
4. Other

Case name Countermeasures for difficult-to-access cleaning locations in the __ line feeder unit

Purpose of improvement Reduction in cleaning time

Target machine Section Subsection Machine No. __

Suggested by Estimated expenses 10,000 yen

Scheduled __/__/__ Scheduled to be

implementation date implemented by

Completion date __/__/__ Implemented by

(Before improvement) (Illustration)

1. There are 100 bolts holding the cover, and these

cannot be removed without a hex wrench.

2. Since removing the cover occupies 80% of the

cleaning time,

3. An excessive amount of time is required, and

cleaning is not performed very often.

4. Since the cover is made of a steel plate, it requires

two persons to remove it.

(After improvement) (Illustration)
1. Changed the steel plate to a transparent polyvinyl
chloride plate, and made it easy for one person to
remove it by dividing the plate into multiple plates.
2. Change the plate mounting method to bell-slotted
holes, making it easy to attach and remove.
3. Since the inside of the equipment is visible, the
cleaning time is more readily decided.

(Effectiveness, and policies after improvement)
Cleaning time: Greatly reduced from 40 minutes to 7 minutes
Cover removal: Reduced the number of persons needed for removal from 2 persons to 1 person

© JIPM

Example of Countermeasures for 7•2 6-8
Generating Sources

Report on Results of Circle Theme Improvements Registration
(Autonomous Maintenance) No.

Circle __ Section __Subsection Leader: __
Serial No.: __-__
Theme: Reduction in cleaning time for __ finishing machine

Reason for selection BM Goal
20 min/day → 5 min/day
Chips were funneled through a chute and scattered on the floor, causing Period: 11/25/19__ - 12/26/19__
excessive time for cleaning. Cleaning time was reduced by means of a
cover to prevent scattering of the chips.

Before improvement After improvement

Results of 5 hr/month Effective 11,500

reduction in amount yen/month
losses

Purging of 18 1. Scattering of filings 2. Leakage of rasaito 3. Leakage of grinding water
evils (4) Scattering of chips
* Circle 7. Scattering of dust 5. Leakage of cutting water 6. Scattering of casting sand
improvements 10. Leakage of air
that were made 13. Leakage of water 8. Leakage of hot solvent 9. Leakage of oil
16. Abnormal sounds
11. Leakage of mist 12. Leakage of odors

14. Leakage of fluids for surface finishing, etc. 15. Omitted work

17. Abnormal heat 18. Abnormal vibration

Graph of Prevention of future Leader's
results recurrences comments

Standardization: 1 case It was extremely difficult to make a cover in

the limited time of the activity, but we were

Issuance of improvement able to eliminate the scattering of chips on

sheet: 5 cases the floor with the cooperation of all members.

Received

Creation of one-point lesson at TPM Departmen Section Subsection

sheet: 5 cases Promotion t Manager Manager Manager

Office

© JIPM

Step 2 Diagnosis Sheet 7•2 6-9

Subsection Section Step 2 of TPM Autonomous Maintenance
Target equipment: Department Diagnosis Sheet for Countermeasures for Generating

Sources and Difficult-to-Access Locations

Diagnosis points Cited items Evaluation points

Is the level from Step 1 being 87 64 0
maintained? The level when Passably clean Slipped back to
Even cleaner than Established in passed is being former condition
Are the conditions maintained
for passing Step 1 Are they changing their viewpoint and when passed daily activities 0
being maintained? uncovering problems? 64 Uncovering almost
8 7 Uncovering no problems at all
Changing their problems a little at
viewpoint and a time
uncovering many
problems rapidly

(Comments) /16

Are the respective 4 32 1 0
generating sources Completely For the most part About half Less than half Not revealed at all
being revealed? revealed

Are the respective 4 32 1 0
amounts generated Completely For the most part About half Less than half Not understood at
understood? understood all

Are the respective 4 32 1 0
generating sources Completely For the most part About half Less than half Not understood at
understood? understood all

Countermeasur Are measures that can 43210

es for be taken within the Results are clearly Tentative results Countermeasures Countermeasures Countermeasures

generating section being taken, and being obtained are being obtained are completed, but are in progress are not being

sources of are results being results are not yet taken

leaks, rust, dirt obtained? obtained

and waste

Progress of What about problems 4 3 2 10
Request Execution in Request in Drafting of plan for Not yet started
counter-measures for which completed and progress progress countermeasures
results are being in progress
for generating countermeasures were obtained

sources requested to other

departments, and are

results being obtained?

(Comments) /20

Have the generating 432 1 0
sources for scattering Completely made For the most part About half Less than half Not made tangible
(chemicals, mist, oil, tangible at all
water, etc.) been made
Prevention of tangible? 4 32 1 0
scattering and Is the amount of Completely For the most part About half Less than half Not understood at
scattering and the understood all
counter- amount of waste 32 1
measures ifor introduced understood? 4 For the most part About half Less than half 0
Are the sources of Completely Not understood at
ntroducing scattering and understood all
waste introducing waste
understood?
43210
Are countermeasures
that can be taken within Results are clearly Tentative results Countermeasures Countermeasures Countermeasures
the section being taken,
and are results being being obtained are being obtained are completed but are in progress are not being
obtained?
What is the status of results are not yet taken
problems for which
requests were made to obtained
other departments, and
are results being 43210
obtained?
Request Request Request in Drafting of plan for Not yet started

completed but completed progress countermeasures

results not yet in progress

obtained

(Comments) /20

Diagnosis date: __/__/__ Total points Pass 80 points or more
Diagnosed by __/100 points
Try again

Diagnosis points Cited items Evaluation points

Have the difficult-to-access cleaning and 43 2 1 0
oiling locations been revealed? About half Less than half Not yet
Have been For the most part
Are countermeasures being taken to 2
make the machine vicinity easy to clean? completely About half

What is the status Are measures being taken to make the revealed
of counter- machine interior easy to clean?
43 1 0
measures for Less than half Not yet
difficult-to-access Do piping and wiring get in the way of Countermeasures For the most part
cleaning and oiling cleaning?
completed
locations?
Are efforts being made to increase the 432 1 0
interval of cleaning and oiling? Countermeasures For the most part About half Less than half Not yet
completed
Are efforts being made to reduce the time
for cleaning and oiling? 4321 0
Not yet started
Are measures that can be taken within the Countermeasures For the most part Countermeasures In planning
section being taken?
completed in progress
What about the problems for which
countermeasures were requested to other 4 4 2 1 0
departments? Effectiveness is Some ef- In progress Under Not yet started
recognized fectiveness consideration
Have preparations been made for Step 3
(creation of cleaning and oiling 43 2 1 0
standards)? Greatly reduced Reduced Reduced In planning Not yet started
somewhat
(Comments)
432 1 0
Countermeasures For the most part About half Less than half Not yet
completed

43 2 10
Request in Drafting of plan for Not yet started
Countermeasures Request progress countermeasures
in progress
completed completed
0
3 21 Not yet started
Preparation For the most part Preparation in
completed
progress

/35

Status of Have the themes been subdivided, and 3 2 1 0
autonomous are the subdivided themes being pursued Adequately Satisfactory Some parts not Not subdivided
with specific numerical values? subdivided and adequately
activities clarified 2 pursued 0
Are the results of PDCA in a form that can Normal Not indicated
be understood? 3 1
Indicated in a 2 Difficult to
manner than is Normal understand
easy to
Are the schedule and results of meetings understand 10
indicated? Difficult to under- Not indicated
3 stand
Indicated in a
manner than is
easy to under-
stand

(Comments)

/9

© JIPM

Procedure for Implementing Step 3 7•2 7-1

Procedure for Implementing Step 3: "Creation of Tentative
Autonomous Maintenance Standards"

Preparation * Step 3 establishes rules so that equipment conditions that do not cause
for Step 3 forced deterioration can be maintained in a short period of time.
activities
♦ Improving the efficiency of cleaning and inspection
1. Preparation of improvements to more easily clean and inspect parts that dirty easily, and to more easily manage

machine parts

2. Recognizing the difference between the level for passing Step 3 and the present level (revealing the issues)
3. Preparation of tentative autonomous maintenance standards and checklists
* Items other than those listed above need to be prepared, the same as for previous steps.
♦ General inspection of "lubrication" (in principle, this is performed in Step 4)
1. Leader education for lubrication management (education through manuals)
2. Education for circle members on lubrication management (correspondence education: One-point lessons)
3. Recognition of general inspection activity requirements
4. Creating a schedule of activities (on a monthly, weekly and daily basis)
5. Preparation of general inspection sheets and disassembly inspection tools for lubrication oil and lubrication equipment
6. Provision of an oil station
7. Making the oil types uniform Implemented by supporting person
8. Observation of pilot organization model machine: Understanding of object of activity
9. One-point lessons on management key points related to lubrication oil and equipment

Implementa- ♦ Improving the efficiency of cleaning and inspection → need to raise the level of visualizing key management points
tion of Step 3 ♦ General inspection of "lubrication"
activities
1. General inspection of lubrication oil Investigation and analysis of the deterioration of oil types used, and changing oil

Changing the oil where the wrong oil type is used

2. General inspection of lubrication Inventory taking of lubrication equipment and locations to be oiled

equipment Identification and countermeasures for problems and minor defects

Check the discharge quantity and destination

3. Improving the efficiency of oiling Reducing the oiling frequency, and making the oil types uniform

Adoption of a central oiling system, and adoption of oilless equipment and parts

4. Creation of criteria and color coding for lubrication oil and equipment problems

Visual management

Revealing key management points (functional parts)

Visualizing key management points (functional parts)

Creation of criteria and color coding to distinguish normal from abnormal

(It is important to create standards for basic conditions and for conditions that are used)

Measurement ♦ Improving the efficiency of cleaning and inspection: Measure the effectiveness visually, the same as in the previous step
of effective- ♦ General inspection of "lubrication"
ness
1. General inspection of lubrication oil Quantity consumed and conditions of deterioration→ Set the oiling period

Oil temperature and coolant conditions → Understanding the appropriate

temperature

2. General inspection of lubrication Effectiveness before and after countermeasures taken for machine
equipment problems

(E.g., oil leakage, status of wear in functional units, etc.)

3. Improving the efficiency of oiling Effect of oiling time and frequency→ Creation of MP system and

engineering sheets

4. Visual management Understanding the effects of visualization and color coding

Circle ♦ Improving the efficiency of cleaning and inspection Implemented the same as in the previous step
meetings ♦ General inspection of "lubrication"

* It is necessary for specialized maintenance personnel to provide guidance and tentatively divide roles for
maintenance work functions

Preventing 1. Creation of a lubrication system diagram, and training of behavior based on lubrication inspection standards
future 2. Verify lubrication and inspection skills (test of level of understanding)
recurrence 3. Creation of tentative autonomous maintenance standards (standards evolved since the Step 2 tentative standards

+ lubrication technology)

4. Insertion of tentative rules in the tentative autonomous maintenance standards to prevent problems with key
management points

5. Training of behavior based on the tentative autonomous maintenance standards
6. Establishment of issues for Step 4: Items that require further improvement
7. Implementation of autonomous diagnoses → Tentative step diagnosis → Final step diagnosis

Advance to Step 4 Tentative diagnosis of all equipment Advance after passing the diagnosis
Final diagnosis on a circle unit basis

© JIPM

Purpose Planning Chart for

Activity item Circl
1 Clarification of tentative standards
2 Unification of tentative standards Date
3 Implementation of inspection
4 Verification of effectiveness
5 Autonomous diagnosis
6 Top executive diagnosis

r Step 3 Activities Department Planning Chart for Step 3 Activities

le Section

7•2

7-2

© JIPM

Tentative Cleaning and

Illustration of cleaning and inspection Machine name:

Date created: __/__/__

Created by: Circle Section Departme

No. Location Implemented

by

d Inspection Standards Tentative Cleaning and Inspection
Standards
Section Subsection Circle Created

Manager Manager Leader by

en Method Frequency Time Clarification
Standard of purpose

Daily Weekly Monthly

7•2

7-3

© JIPM

Illustration of cleaning and inspection Tentative Oili

Date created: __/__/__ Circle Machine name:
Created by:
Section
No. Location Implemented

by

ing Standard Tentative Oiling Standard

Section Subsection Circle Created

Manager Manager Leader by

Departmen Frequency Time Clarification
Standard Method of purpose

Daily Weekly Monthly Other

7•2

7-4

© JIPM

Tentative Retight

Line Headquarters/Business Department Department
Machine name: Section

Control No.:

Illustration of location to be Name of Retightening Point
retightened retightening standard

location

tening Standards Tentative Retightening Standards

(Date created: __/__/__)

Section Subsection Line Created

Manager Manager Leader by

Retightening Retightening time Frequency of
retightening
tools (min per
Weekly 10-days Monthly
retightening) Daily

7•2

7-5

© JIPM