JIPM-TPM.Sample-Forms-Editing-2

Checksheet for Cleaning, Inspection,
Oiling and Retightening

No. Location Standard Frequency
Daily Weekly Monthly

* The No. and the location should agree with the Inspected
standard by

* Cleaning and inspection methods should be Seal of
carried out in accordance with standards approval

Checksheet for Cleaning, Inspection, 7•2 7-6
Oiling and Retightening

Department © JIPM

Section Checked on date/month

Machine name:
Circle

Lubrication Oil Label 7•2 7-7
Lubrication Oil Label

Oil label and frequency Record the oil type name

Daily Example 1 Lubrication oil, operating oil, grease, etc.
(red)
Example 2 Grease bearing oil, compressor oil, lubrication
oil for sliding guide surface, turbine oil, etc.

Example 3 Directly record the product name, number, etc.

Size

Large: 100 mm dia.

Medium: 50 mm dia.

Small: 25 mm dia.

Weekly Ultra small: 12.5 mm dia.
(orange)

Monthly Material
(Green) • Oil resistant and solvent resistant

Other
• The circumference of the large and medium sized monthly

labels are perforated, and designed to be torn off. Devise
ways to use these labels in every workplace.

Other
(Blue)

© JIPM

Example of Visual Management 7 • 2 7 - 8 - (1)

Example of Visual Management

Before improvement After improvement Before improvement After improvement

15

Operation of the cooling fan Visual management was There was no on/off position Visual management was
was verified using one’s hands achieved by attaching a indicator for the switch. achieved by using an arrow
to check the airflow of the fan. streamer to the airflow inlet. indicator for the on/off position.
Before improvement
Before improvement After improvement After improvement

26

The prescribed pressure was Visual management was There were no on/off position Visual management was
managed by observing the achieved by coloring the meter
gradations on the meter. so that the operator can check indicators for the buttons. achieved by affixing on/off
whether the needle is in the
Before improvement green zone. indicators.

After improvement Before improvement After improvement

37

Looseness of the attaching Visual management was The residual amount of stock Visual management was
screw was verified by using a achieved by inscribing was known only when stock ran achieved by inscribing a
hex bolt to retighten it. matching marks when the out. remainder warning mark inside
attaching screws were
Before improvement tightened. the case.

After improvement Before improvement After improvement

46

The button lamp could not be Visual management was The lamp could not be managed Visual management was
managed because it had no achieved by placing a lamp ON
lamp ON indicator. indicator mark in the corner of because it had no lamp ON achieved by inscribing a lamp
the button.
indicator. ON indicator mark around the

lamp.

© JIPM

Example of Visual Management 7•2 7 - 8 - (2)

Example of Visual Management

(1) Pressure indicator: (3) Flow direction indicator for fluids:
Color-code the meter so that the permissible range of Facilitate operation by clarifying the type and
the meter can be seen at a glance if the pressure direction of fluids flowing inside pipes.
deviates from the normal.

(2) Valve open/close indicator:
On valves for which it is difficult to know whether it
is open or closed, hang an indicator tag so that the
open/close status can be seen at a glance.

(4) Use clear labeling on the tool shed: (5) File placement indicator: Clearly indicate the
Clearly label each tool in the tool shed so that you can placement of the file by drawing a picture across the
tell at a glance where each tool is, and make labels so spines of the entire set of files.
that the usage status and location where each tool
should be returned are clear.

© JIPM

Autonomous Mai
Table of Changes in Cleaning, Inspec

Circle

Time

Cleaning time
Inspection time

__/__

intenance Step 3: Table of Changes in Cleaning, Inspection,
ction, Oiling and Retightening Times Oiling and Retightening Times

Section Department __/__

7•2

7-9

© JIPM

Step 3 Diagnosis Sheet 7•2 7 - 10

Subsection Section TPM Autonomous Maintenance Step 3
Target equipment: Department Diagnosis Sheet for Creating Cleaning and Oiling

Standards

Diagnosis points Evaluation points

Step 1 Are clean conditions being maintained? 5 4 3 2 1
Maintenance and
improvement of Cleaner than Maintained as Passably Below the level Dirty
conditions when initial when passed when passed when passed
cleaning step was
Is "cleaning is inspection" being 5 4 32 1
passed observed, and are problems being Being Cleaning is Could do better Marking time Regressing
identified? identified inspection
Purpose
Are workers identifying problems with 5 4 3 2 1
Provision of No change in Lesser detail
base conditions greater detail, and is the next step after Skills improved Skills improved Greater detail
details
improving the skill of members remarkably

understood?

(Comments) /15

Diagnosis points Evaluation points

Step 2 Are improvements being made to oiling, 5 4 321
Could do
Status of follow-up on and are these improvements leading to Maintainability Oiling Not yet No
generating sources, better improved improvement
increased maintainability? is improved
difficult-to-access 4
cleaning and oiling Are plans being drafted again for those 5 Plan 321
locations, and counter- items which did not achieve adequate Meticulously drafted
results from the countermeasures? Drafting of plan Drafting of plan Not yet
measures planned 3 in progress scheduled started
Almost
Purpose Are further measures needed? 4 completely 210
unneeded
Improve (Are any omissions in the counter- No blind Could do Not yet Greatly
reliability and measures?) spots better needed
maintainability

(Comments) /14

Diagnosis points Evaluation points

Details of cleaning and Where? Has the range of the 4 3 2 1
inspection standards Who? division of oil Firmly decided Decided Passably Not decided
responsibilities been
Purpose decided? 3 2 1
Maintenance Decided Passably Not decided
and control of By what Are the methods and tools 4
cleaning an method? for cleaning and Firmly decided 3 2 1
d inspection inspection decided? Could do better Not yet Not decided

When? Are the period and time 4 3 2 1
How much? for cleaning and Set appropriately Could do better Not yet Unclear

inspection set appro- 3 2 1
priately? Could do better Procedure is Not recorded
observed, but not
What? Is the object of cleaning 4 /20
and inspection clarified? Clarified clearly

Is the cleaning status recorded on 4
checksheets, and is this Observance of this
conscientiously observed? procedure can be

seen visually

(Comments)

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

Diagnosis points Evaluation points

Details of oiling Where? Has the range of the division of oil 3 2 1
standard responsibilities been decided? Firmly decided Passably Not decided
Who?
Purpose Are the oiling methods and tools decided, 3 2 1
Maintenance and control By what and in a fixed location (5S of the storage In a fixed position Passably Not decided
method? location)?
of oiling Are the period and time set appropriately? 3 2 1
When? Firmly decided Passably Not decided
How much?

Are the type and quantity of oil decided? 3 2 1

What? Decided Passably Not yet decided

Is the object of oiling clarified? 321

Clarified Passably Unclear

clean, is the oil easy to see, and is the oiler
functioning normally?

relevant Is the automatic oiling equipment 3 2 1
equipment functioning normally? Passably
Functioning Not functioning
normally normally

Are the grease cap and oil cap functioning
normally?

Have all systems been checked to verify that the oiling 3 21
equipment is functioning to the maximum level? Verified For the most part Not yet started

Is the oiling inlet dirty? Also, are means being devised to 3 2 1
prevent it from being dirtied? Good Passably Dirty

Is a checksheet used to keep records, and is this done 3 2 1
conscientiously? Observance of this Passably Not clear whether
procedure can be procedure is being

seen visually observed

(Comments) /27

Diagnosis points Evaluation points

Status of autonomous Are the overall schedule and the 4 3 2 1
maintenance current month schedule clearly Clearly defined Passably Could do better Unclear
activities defined?

Purpose Is a record documenting losses 4 3 21
Development of being kept so that problems can Passably Could do better Not recorded
be reduced? Conscientiously
autonomous recorded
maintenance
Activity board Are the results of 4 3 21
Passably Could do better Not displayed
and meetings countermeasures made apparent? Made easy to
3
understand Passably

Are standards created in 4 3 2 1
meetings, and is the importance of Thoroughly Passably Could do better
observing these standards Not
thoroughly communicated? 3 thoroughly
Passably
Is care taken so that all personnel 4 2 1
know the number of improvement Could do better
suggestions and their Easy to Difficult to
implementation? understand understand

Are instructions and activities 4 2 1
Could do better Not yet
between members and managers Firmly executed

firmly executed?

(Comments) /24

© JIPM

Procedure for Implementing Step 4 7•2 8-1

Procedure for Implementing Step 4: "General Inspection"

* Step 4 identifies and takes countermeasures for problems (minor defects) related to the structure and functioning of
equipment, as well as problems deduced logically, and implements "the equipment as it should be" (as a rule, implemented
as a substep).

Preparation 1. Identification of general inspection items (lubrication, tightening, pneumatics, hydraulics,
for general drive, electrical, measuring equipment, etc.)
inspection
and 2. Preparation of educational materials for education and training (manuals, cut-out models,
education assembly demo machines, videos, etc.)

3. Daily schedule for education and training (education for Leaders and Managers)

4. Training of Instructors (Maintenance, Engineering, TPM Promotion Office, etc.)

Im- Implemen- 1. Implement education for Leaders and Managers Managed by Leaders
plement- tation of (education through manuals) and Managers
ation of general
general inspection 2. Prepare correspondence courses for Circle Members.
in- education 3. Correspondence courses for Circle Members (one-point lessons)

spection 1. Identify minor defects and attach tags (keep a record in the problem list used since Step 1).
2. Create a countermeasures plan and countermeasures proposal (restoration and
by
improvement) for minor defects (one’s own assigned area working together with other
subject: Implemen- assigned areas).
1-2 tation of
months/ general 3. Devise means to improve the efficiency of cleaning and inspection, and draft an improvement
subject inspection plan.

4. Reveal key management points (functional parts). (For those items already identified in Step
1, dig further and identify additional items).

Restoration 1. Restore and improve identified minor defects (one’s own assigned area working together with
and other assigned areas).
improve-
ment of 2. Implement improvements to make cleaning and inspection more efficient.
minor 3. Provide the basic conditions for management key points that have been revealed.
defects 4. Increase the degree of visualization of physically latent defects for management key points

(reinforce the contents of countermeasures taken in Step 2).

5. Create standards (standardization of basic conditions and conditions used) for determining

problems in management key points, and create a color code scheme → Visual management
6. Measure the effectiveness of restoration, improvements, improved efficiency, visualization,

color coding, etc. → Reflect these measurements when setting the periods for cleaning and
inspection

7. Create MP information for a case example of improvement and increased efficiency →
Create engineering sheets.

Preventing 1. Create tentative standards for general inspection by subject.
future Insert into the tentative standards the tentative rules (basic conditions and the standard for
recurrence determining problems with conditions in use) for preventing problems in management key .

points
2. Training and observance of behavior based on tentative standards.
3. Check the inspection skills for general inspection by subject (test of level of understanding)
4. Implement autonomous diagnoses and tentative diagnoses of general inspection by subject.
5. Implement step diagnoses of general inspection by subject (substep diagnoses).

Advance to Step 5 Advance after passing all general inspection items.

© JIPM

Purpose Planning Chart for

Activity item C
1 Identification of subject
2 Creation of implementation plan Date
3 Creation of educational materials
4 Education of leaders
5 Evaluation of skills
6 Correspondence education
7 Implementation of general inspection
8 Autonomous diagnosis
9 Top Executive diagnosis

r Step 4 Activities Planning Chart for Step 4 Activities

Circle Section Department

7•2

8-2

© JIPM

Identification of Subjects (Analysis of Machining 7•2 8-3
Work and Implementation of General Inspection)

Case Example of Implementing General Inspection:
Pneumatic System

Analyze the machining work of the target Create a flowchart and For each general Create a Inspection
equipment, understand the structure and clarify system diagram of the inspection part, general Restoration
the system, functions and required conditions system and clarify the identify the inspection Im-
general inspection inspection items and check- provement
parts. perform a Know- sheet.
Why analysis.

System that Filter • Draining
forms the • Inside surface of case is dirty
machining Pressure • Damaged deflector
work control valve • Element clogged up with dirt
• Damaged baffle plate
Lubrication Oiler • Perpendicularity of filter
system • Air leaking from pipe connector
Piping joints
Hydraulic Directional • Operating state of pressure control
system control valve valve

Ma- System that Pneumatic Flow control • Zero point of pressure valve
chin- positions system valve • Control range indicator of pressure
ing the
work machining Actuator gauge
work • Air leaking from pipe connector

System that Kinetic • Verification of oil quantity
supports system • Deterioration of oil and contamination

continuity of Drive by waste or foreign matter
machining transmission • Verification of oil drip quantity
• Air leaking from pipe connector
work system
• Crushed or damaged pipes
Electrical • Air leaking from joints
control
system • Operating condition of directional
control valve
Abnormal noise, temperature or odor

• Air leaking from exhaust outlet
• Air leaking from pipe connector

• Operating condition of flow control valve
• Matching mark for flow adjustment
• Air leaking from pipe connector

• Air leaking from pipe connector
• Air leaking from head cover or rod cover
• Damaged or worn piston rods
• Operating condition of pistons
• Loose actuator attaching bolts
• Looseness or play in connectors of

machining work

© JIPM

Planning Chart for Implementation o

Inspection Purpose Correspondence Classro
education education work
by subject by recipient

I Basic approach to • To understand what machining work is, and why Education for
general inspection of defects and equipment losses occur. Department Managers
equipment • The oil lubrication, grease lubrication and cutting oil and Section Managers Fundamenta
• Explain us
Oil lubrication system systems help the rotating and sliding parts move Education for Leaders
smoothly, and improve the efficiency of the machine. point shee
Grease lubrication However, quality defects and equipment losses arise if Inspection
system there is a problem with areas such as lubrication oil, and metho
Cutting fluid system grease, cutting oil or pumps. • Explain us
videos and
• Therefore, we will learn the methods and know-how textbooks

concerning general inspection points for each area. Education of operators

II Hydraulic and • The purpose of the hydraulic system is to smooth the Education for Fundamenta
pneumatic systems machining of work in linear and rotating operations by Department Managers • Explain us
means of oil pressure. However, quality defects and and Section Managers
equipment losses arise if there is a problem with the Education for Leaders point shee
operation oil tank or pressure control valve in the Inspection
hydraulic system. and metho
• Explain us
• The purpose of the pneumatic system is to smooth the videos and
movement of the machining work by means of air textbooks
pressure. However, quality defects and equipment
losses arise

if there is a problem in areas such as the air pressure Education of operators
source, pressure control valve, oiler or actuator in this
system.
• Therefore, we will learn the methods and know-how
concerning general inspection points for each area.

III Drive, transmission • The purpose of this system is to mechanically transmit Education for Fundamenta
and kinetic systems energy, convert that energy into motion, and to Department Managers • Explain us
continuously machine the work. However, quality and Section Managers
defects and equipment losses arise if there is a point shee
problem in areas such as the motor, belts, gears or Education for Leaders Inspection
and metho
gear converters in this system. Explain us
videos and
• Therefore, we will learn the methods and know-how textbooks
concerning general inspection points for each area.

Education for operators

IV Electrical control • The purpose of this system is to maintain the Education for Fundamenta
systems relationships among the form position and continuity of Department Managers • Explain us
the machining work, and to transform the required and Section Managers
amount of electrical energy to the required location at Education for Leaders point shee
the required time. However, quality defects and Inspection
equipment losses arise if there is a problem in areas of and metho
this system. Explain us
videos and
• Therefore, we will learn the methods and know-how textbooks

concerning general inspection points for each area Education for operators

IV Fasteners and • The purpose of fasteners is to ensure the reliable Education for Fundamenta
equipment main body operation of the various systems by securing various Department Managers • Explain us
parts in a balanced way to the main body. The and Section Managers
equipment main body is the reference plane and point shee
source of rigidity that balances the continuity of Education for Leaders Inspection
and metho
machining. However, quality defects and equipment Explain us
losses arise if there is a problem in areas of this videos and
system. textbooks

• Therefore, we will learn the methods and know-how

concerning general inspection points for each area. Education for operators

of Autonomous Maintenance Step 4 Planning Chart for Implementation

Group education OJT education

oom Practical Check Autonomous diagnosis Restoration
k work level of (general inspection) and Diagnosis Pass
understanding improvement

(3 hours) (3.5 hours) (1.5 hours) Model equipment Restoration Verification Stick on
and by the
als Experience Implementation Creation and improvement Promotion compli-
sing one- and training of checks inspection of general
ets using a cut- How to create inspection Verification Office ance
certifi-
n points out model general checksheets using cate
ods and a checksheets
sing prototype inspection sheets Verification of safety emblem
• Explain using observance items Removing tags

d one-point Attaching tags
sheets

Horizontal replication

als Experience Implementation Model equipment Improvement Verification Stick on
sing one- and training of checks Verification by the
Creation and Promotion compli-
ets using a cut- How to create inspection of general using
out model general inspection checksheets Office ance
n points and a certifi-
ods prototype inspection sheets checksheets Removing tags cate
sing
• Explain using Verification of safety emblem
one-point compliance items
d sheets
Attaching tags

Horizontal replication

als Experience Implementation Model equipment Improvement Verification Stick on
sing one- and training of checks Verification by the
Creation and Promotion compli-
ets using a cut- How to create inspection of general using
out model general inspection checksheets Office ance
n points and a certifi-
ods prototype inspection sheets checksheets Removing tags cate
sing
• Explain using Verification of safety emblem
one-point compliance items
d sheets
Attaching tags

Horizontal replication

als Experience Implementation Model equipment Improvement Verification Stick on
sing one- and training of checks Verification by the
ets using a cut- Creation and Promotion compli-
How to create inspection of general using
out model general inspection checksheets Office ance
n points and a certifi- 7•2
ods prototype inspection sheets checksheets Removing tags cate
sing
Explain using Verification of safety emblem
one-point sheets compliance items
d
Attaching tags

Horizontal implementation

als Experience Implementation Model equipment Improvement Verification Stick on
sing one- and training of checks Verification by the
ets using a cut- Creation and Promotion compli-
How to create inspection of general using
out model general inspection checksheets Office ance
n points and a certifi-
ods prototype inspection sheets checksheets Removing tags cate 8-4
sing
Explain using Verification of safety emblem
one-point sheets compliance items
d
Attaching tags

Horizontal replication

Note: Each subject is performed on a monthly basis.

© JIPM

Example of Educational Materials 7 • 2 8 - 5 - (1)

Educational Materials for Autonomous Maintenance Step 4

Flowchart of pneumatic system

(1) (2) (3) (4) (5) (6) (7) (8)
→ Oiler → → Actuator
Air pressure Pressure Piping Directional Flow
source → Filter → control and → control valve → control
system valve joints valve

System diagram of pneumatic system

Pneumatic system general inspection parts
(1) Air pressure source system
(2) Filter
(3) Pressure control valve
(4) Oiler
(5) Piping and joints
(6) Directional control valve
(7) Flow control valve
(8) Actuator

Filter general inspection items
(1) Draining
(2) Dirt on inside surface of case
(3) Damaged deflector
(4) Dirty and clogged up element
(5) Damaged baffle plate
(6) Perpendicularity of filter
(7) Air leaking from piping connectors

© JIPM

Operator Educa

Part Filter Inspectio

Inspection method and criteria Direction of improveme
"NO"

{ Remove the filter element and inspect for dirt { In the case of light dirt, clean

and clogging blowing air from the inside of

element

{ If clogged, replace with a new

element

ational Materials Example of Educational Materials

on item Check filter element

ent if Know-Why (why is this improvement
necessary?)

by { Element is clogged
the

Pressure decreases
w Actuator operates unevenly

Variation in movement of machining work
Quality defects
Speed decreases

Failure stoppage
Misoperation of actuator

Failure stoppage
Contamination by waste, dust or foreign matter

Abnormal wear of directional control valve
Internal leakage
Uneven operation of actuator
(Following is the same as above)

Sludge in the flow control valve
Reduced flow rate

7 • 2 8 - 5 - (2)

© JIPM

Example of Educationa

Example of Educational Materials 7 • 2 8 - 5 - (3)

al Materials (Textbooks)

© JIPM

General Inspec

Education Schedule
Lubrication system

Hydraulic and pneumatic system

Drive system

Electrical system

Machine elements system

System 12345678
Interval (month)

ction Education Education Schedule

Education for Department
Managers and Section Managers

Education for Leaders

8 9 10 11 12 7•2

Correspondence Courses for
Operators

8-6

© JIPM

Verification of Level of Understanding 7•2 8-7

Checksheet for Level of Understanding:
General Inspection of Grease and Lubrication Systems

Assigned area
Name

(Problem) Read the following text carefully, make one selection from the choices enclosed by braces { } that fits
in the space enclosed by parentheses ( ), and write that choice in the parentheses.

(1) Depending on the type, lubrication location and operating conditions of the machine to be lubricated, there are

various types of lubrication fluids. However, these types can be largely divided into three categories: Liquid

lubricants, ( ), and solid lubricants.

{semi-liquid lubricants / semi-solid lubricants}

(2) Grease comprises a thickening agent, a base oil and a ( ). This grease preserves

( ) because the thickening agent, which is fibrous and has a ( ) structure,

incorporates oil.

{lubrication oil / semi-solid / mesh / additive agent}

(3) General inspection of grease

• Examine the ( ) indicated on the new oil can, and verify whether it is the same as that

prescribed by the machine ( ).

{manufacturer name / oil type / specifications}

•( ) the grease which has been pumped and check whether it has been contaminated by waste,

dust or ( ). If there is a problem, inspect all ( ).

{part / sample / equipment / foreign matter}

• By steadily performing general inspection of the grease, one can prevent overheating and ( )

on lubricated parts, as well as oil leaks and ( ) that arise from those problems.

{waste and dust / loss of oil film / abnormal wear}

© JIPM

Correspondence Ed

Circle Section

Contents of correspondence Attendees

education

Time OJT or Instructor Name Daily Atten- Daily A
OFF-JT sched- dance sched- d
Subject required
ule ule

ducation Schedule Correspondence Education Schedule

Section Subsection Circle
Manager Manager Leader

Department

Education schedule

Atten- Daily Atten- Daily Atten- Daily Atten- Daily Atten- Daily Atten- Daily Atten-
dance sched- dance sched- dance sched- dance sched- dance sched- dance sched- dance

ule ule ule ule ule ule

7•2

8-8

© JIPM

Grease Lubrication System Part Grease Ge

Inspection Inspection method Inspection
item and criteria results

(1) Check the oil type. { Examine the oil type
indicated on the new oil
can, and verify whether it is
the same as that
prescribed by the machine
specifications.

(2) Check that the grease { Sample the grease which

is not contaminated by has been pumped and use

waste, dust or foreign a measuring instrument to

matter. check for the presence of

contaminants.

(3) Check that the grease { Visually inspect the grease

is not contaminated by sample to check for white

moisture. turbidity.

(4) Check that the grease { Visually inspect the grease

is not contaminated by to check for air bubbles

air bubbles. and white turbidity.

eneral Inspection Checksheet General Inspection Checksheet

Improvement Classification of factors
details
Fixed Semi-fixed Variable

7•2

8-9

© JIPM

Schedule for General Inspectio

No. Part Circle Section Factor Department
Nature Nature of
of problem improvement Fixed Semi- Insp
fixed
Variable Nuts Lubri- D
and cation
bolts

on and Correction of Problems Schedule for General Inspection and
Correction of Problems
Machine name: Created by:
Schedule
pection subject
Person
Drive Elec- Pneu- Hy- -in-
trical matic drau
lic Charge

7•2

8 - 10

© JIPM

General Inspection Checksheet 7•2 8 - 11

General Inspection Checksheet

Date : __/__/__

Case name Circle Section Department Machine No. __
Purpose of improvement __/__/__
Target machine __/__/__ Classification
Part Scheduled to be
Suggested by implemented by
Implemented by
Completion date
(Illustration)
(Before improvement)

(After improvement) (Illustration)

(Effectiveness, and policies after improvement)

© JIPM

List for General Inspection a

No. Description of problem Counterme
Classification
Description Description of Pe

improvement

{ Reduced functionality Part Measure
{ Reduced quality

{ Factor fixed Location Measures

{ Inspection fixed Loss Other

{ Inspection time

{ Reduced functionality Part Measure
{ Reduced quality

{ Factor fixed Location Measures

{ Inspection fixed Loss Other

{ Inspection time

{ Reduced functionality Part Measure
{ Reduced quality

{ Factor fixed Location Measures

{ Inspection fixed Loss Other
{ Inspection time

{ Reduced functionality Part Measure
{ Reduced quality

{ Factor fixed Location Measures

{ Inspection fixed Loss Other
{ Inspection time

{ Reduced functionality Part Measure
{ Reduced quality

{ Factor fixed Location Measures

{ Inspection fixed Loss Other
{ Inspection time

{ Reduced functionality Part Measure
{ Reduced quality
Location Measures
{ Factor fixed

{ Inspection fixed Loss Other
{ Inspection time

{ Reduced functionality Part Measure
{ Reduced quality
Location Measures
{ Factor fixed

{ Inspection fixed Loss Other
{ Inspection time

and Correction of Defects List for General Inspection and
Correction of Defects
Circle Section Department

easures Effectiveness
erson-in-charge
Description Effectiveness

es taken within section →
s taken at other sections

es taken within section →
s taken at other sections

es taken within section →
s taken at other sections

es taken within section →
s taken at other sections

es taken within section →
s taken at other sections

es taken within section → 7•2
s taken at other sections

es taken within section →
s taken at other sections

8 - 12

© JIPM

Step 4 Diagnosis Sheet 7 • 2 8 - 13 - (1)

Application Form for Autonomous Section / Team Application Section Leader
Maintenance Diagnosis name date Manager
Autonomous Maintenance Diagnosis
Sheet Assembly line to
be diagnosed
Step 4-1: General Inspection
(Lubrication) Desired __/__/__

Diagnosis Autonomous Section Top diagnosis date
Manager Executive
Diagnosis date __/__/__ __ points Pass Fail

and time __:__ - __:__

Diagnosed by Pass level
Sum of (Level points in items 1 - 6)

Autono- Section Top

mous Manager Executive

90 points or 85 points 80 points

more or more or more

Bad Poor Fair Somewhat Good

Diagnosis Points of good Sugges-
Item
diagnosis 20 40 60 80 100 tions
Maintenance point
and control points points points points

1. Skills (Are operation and maintenance being performed for Steps 1 - 3?)
education
• Are countermeasures for generating sources being
2. General adequately maintained?
inspection
• Are the improvement conditions satisfactory for
3. Safety
4. Site countermeasures for difficult-to-access cleaning

Diagnosis locations?
(Lubrica
tion) • Have cleaning and oiling standards been completed, and
are they being utilized accordingly?
5. Tentative
autonomous 1 23 4 5
standards points points points points
inspection point

• Are Leaders and Circle Members actively creating one-

point textbooks and raising their level of skill?

• Have all members mastered general inspection skills?

• Are the items of education steadily being inspected

• Are problem locations being identified through inspection?

• Are countermeasures being taken for locations where

problems were identified?

• Are minor defects related to safety being identified, and

are countermeasures being taken?

• Are labels properly stuck to oiling locations, and are
means being devised to enable oiling without omissions?

• Is the correct oil type being used?

• Is the amount of oiling appropriate?

• Is there any oil deterioration?

• Are oil pipes clogged or damaged?

• Is the oil to be supplied always available?

• Are oilers and oil lubricators managed by oil type?

• Check for oiler and nipple damage and check for any
adhering waste or dust.

• Is the oiler station managed by oil type? Is it always
covered? Is there any adhering waste or dust? Is it in the
proper position?

• Have tentative inspection standards been prepared?

• Have improvements been made to reduce the number of
inspection items?

• Have improvements been made to make inspection
easier?

• Are the inspection methods and period appropriate?

• Are means being devised so that inspection is performed
steadily, and without omissions?

© JIPM

Step 4 Diagnosis Sheet 7 • 2 8 - 13 - (2)

Application Form for Autonomous Section / Team Application Section Leader
Maintenance Diagnosis name date Manager
Autonomous Maintenance Diagnosis
Sheet Assembly line to
be diagnosed
Step 4-2: General Inspection
(Hydraulic and pneumatic) Desired __/__/__

Diagnosis Autonomous Section Top diagnosis date
Manager Executive
Diagnosis date __/__/__ __ points Pass Fail

and time __:__ - __:__

Diagnosed by Pass level
Sum of (Level points in items 1 - 6)

Autono- Section Top

mous Manager Executive

90 points or 85 points 80 points

more or more or more

Bad Poor Fair Somewhat Good
good
Diagnosis Points of Sugges-
Item 40 60 80 100 tions
diagnosis 20 points points points points
Maintenance point
and control 23 4 5
(Are operation and maintenance being performed for Steps 1 - 3?) points points points points
1. Skills
education • Are countermeasures for generating sources being

2. General adequately maintained?
inspection
• Are the improvement conditions satisfactory for
3. Safety countermeasures for difficult-to-access cleaning
4. Site locations?

Diagnosis • Have cleaning and oiling standards been completed, and
(Hydraulic
and are they being utilized accordingly?
pneumatic)
(Including 1
water)
point
5. Tentative
autonomous • Are Leaders and Circle Members actively creating one-
standards
inspection point textbooks and raising their level of skill?

• Have all members mastered general inspection skills?

• Are the items of education steadily being inspected

• Are problem locations being identified through inspection?

• Are countermeasures being taken for locations where
problems were identified?

• Are minor defects related to safety being identified, and
are countermeasures being taken?

• Check for leaks and bleeding from pipes and equipment

• Is the equipment dustproof?

• Check for abnormal noise or vibration in the pump motor.
Check for sounds at the beat frequency and abnormal
odors in the switching valve, solenoid, etc.

• Check the oil quantity and temperature of the oil pressure
unit.

• Are the air 3-point sets being used correctly (oil quantity,
filter dirt, etc.)?

• Check the hose mounting condition, and check for any
vibration, dirt and breakage.

• Are the pipes lying on the ground where they should not
be? Are they properly maintained?

• Are the pipes easy to inspect and maintain?

• Is the pressure gauge normal (indicator is appropriate and
easy to see)?

• Have tentative inspection standards been prepared?

• Have improvements been made to reduce the number of
inspection items?

• Have improvements been made to make inspection easier?

• Are the inspection methods and period appropriate?

• Are means being devised so that inspection is performed
steadily, and without omissions?

© JIPM

Step 4 Diagnosis Sheet 7 • 2 8 - 13 - (3)

Application Form for Autonomous Section /Team Application Section Leader
Maintenance Diagnosis name date Manager
Autonomous Maintenance Diagnosis
Sheet Assembly line to
be diagnosed
Step 4-3: General Inspection
(Drive) Desired __/__/__

Diagnosis Autonomous Section Top diagnosis date
Manager Executive
Diagnosis date __/__/__ __ points Pass Fail

and time __:__ - __:__

Diagnosed by Pass level
Sum of (Level points in items 1 - 6)

Autono- Section Top

mous Manager Executive

90 points or 85 points 80 points

more or more or more

Bad Poor Fair Somewhat Good
good
Diagnosis Points of Sugges-
40 60 80 100 tions
Item diagnosis 20 points points points points

point 23 4 5
points points points points
Maintenance (Are operation and maintenance being performed for Steps 1 - 3?)
and control
• Are countermeasures for generating sources being
adequately maintained?

• Are the improvement conditions satisfactory for

countermeasures for difficult-to-access cleaning

locations?

• Have cleaning and oiling standards been completed, and
are they being utilized accordingly?

1

point

1. Skills • Are Leaders and Circle Members actively creating one-
education point textbooks and raising their level of skill?

• Have all members mastered general inspection skills?

2. General • Are the items of education steadily being inspected

inspection • Are problem locations being identified through inspection?

• Are countermeasures being taken for locations where
problems were identified?

3. Safety • Are minor defects related to safety being identified, and

are countermeasures being taken?

4. Site Diagnosis • Check for wear and deterioration of the V-belt. Check

(Drive) for wear and misalignment of the pulley.

• Is the tension of the V-belt appropriate?

• Are the direction of rotation and the dimensions of the belt

in use managed visually in the V-belt cover?

• Is an adequate amount of lubricating oil reaching the area

between the pin and bushings of the chain?

• Check for elongation and misalignment of the chain.
Check for interlocking of the sprocket due to wear.

• Check for overheating, vibration and noise in the bearing
due to bending of the shaft, eccentricity, loosening of the
locking bolts, depletion of oil, etc.

• Check for play (looseness of bolts) in the shaft, keys and

couplings.

• Check for abnormal noise in the gears, reduction gears, etc.

• Is oiling of the gears and reduction gears appropriate, and

is any heat being generated?

5. Tentative • Have tentative inspection standards been prepared?

autonomous • Have improvements been made to reduce the number of

standards inspection items?

inspection • Have improvements been made to make inspection easier?

• Are the inspection methods and period appropriate?

• Are means being devised so that inspection is performed
steadily, and without omissions?

© JIPM

Step 4 Diagnosis Sheet 7 • 2 8 - 13 - (4)

Application Form for Autonomous Section /Team Application Section Leader
Maintenance Diagnosis name date Manager
Autonomous Maintenance Diagnosis
Sheet Assembly line to
be diagnosed
Step 4-4: General Inspection
(Electrical) Desired __/__/__

Diagnosis Autonomous Section Top diagnosis date
Manager Executive
Diagnosis date __/__/__ __ points Pass Fail

and time __:__ - __:__

Diagnosed by Pass level
Sum of (Level points in items 1 - 6)

Autono- Section Top

mous Manager Executive

90 points or 85 points 80 points

more or more or more

Bad Poor Fair Somewhat Good
good
Diagnosis Points of Sugges-
40 60 80 100 tions
Item diagnosis 20 points points points points

point 23 4 5
points points points points
Maintenance (Are operation and maintenance being performed for Steps 1 - 3?)
and control
• Are countermeasures for generating sources being
adequately maintained?

• Are the improvement conditions satisfactory for

countermeasures for difficult-to-access cleaning

locations?

• Have cleaning and oiling standards been completed, and
are they being utilized accordingly?

1

point

1. Skills • Are Leaders and Circle Members actively creating one-

education point textbooks and raising their level of skill?

• Have all members mastered general inspection skills?

2. General • Are the items of education steadily being inspected

inspection • Are problem locations being identified through inspection?

• Are countermeasures being taken for locations where
problems were identified?

3. Safety • Are minor defects related to safety being identified, and
are countermeasures being taken?

4. Site Diagnosis • Are indicator plates attached to the electrical distribution,

(Electrical) control and operation panels?

• Is the temperature of the electrical distribution, control

and operation panels high?

• Are the electrical distribution, control and operation

panels dirty (water, oil and waste)?

• Check for dirt and damage in the cover packing and filters

of the electrical distribution, control and operation panels.

• Check for abnormalities (overheating, damage, unstable
wiring) in the wiring and connections.

• Check for overheating, abnormal noise and vibration in
the motors.

• Are sensors properly installed (position, contact and
looseness)?

• Is the sensor dirty (water, oil and waste)?

• Check for sensor breakage. Check the mounting

condition of the lead wires. Are measures being taken to

prevent breakage?

5. Tentative • Have tentative inspection standards been prepared?

autonomous • Have improvements been made to reduce the number of

standards inspection items?

inspection • Have improvements been made to make inspection easier?

• Are the inspection methods and period appropriate?

• Are means being devised so that inspection is performed
steadily, and without omissions?

© JIPM

Step 4 Diagnosis Sheet 7 • 2 8 - 13 - (5)

Application Form for Autonomous Section /Team Application Section Leader
Maintenance Diagnosis name date Manager
Autonomous Maintenance Diagnosis
Sheet Assembly line to
be diagnosed
Step 4-5: General Inspection
(Nuts and bolts) Desired __/__/__

Diagnosis Autonomous Section Top diagnosis date
Manager Executive
Diagnosis date __/__/__ __ points Pass Fail

and time __:__ - __:__

Diagnosed by Pass level
Sum of (Level points in items 1 - 6)

Autono- Section Top

mous Manager Executive

90 points or 85 points 80 points

more or more or more

Bad Poor Fair Somewhat Good
good
Diagnosis Points of Sugges-
Item 40 60 80 100 tions
diagnosis 20 points points points points
Maintenance point
and control 23 4 5
(Are operation and maintenance being performed for Steps 1 - 3?) points points points points
1. Skills
education • Are countermeasures for generating sources being

2. General adequately maintained?
inspection
• Are the improvement conditions satisfactory for
3. Safety countermeasures for difficult-to-access cleaning
4. Site locations?

Diagnosis • Have cleaning and oiling standards been completed, and
(Nuts and
bolts) are they being utilized accordingly?

5. Tentative 1
autonomous point
standards
inspection • Are Leaders and Circle Members actively creating one-
point textbooks and raising their level of skill?

• Have all members mastered general inspection skills?

• Are the items of education steadily being inspected

• Are problem locations being identified through inspection?

• Are countermeasures being taken for locations where

problems were identified?

• Are minor defects related to safety being identified, and

are countermeasures being taken?

• Check for looseness of nuts and bolts.

• Check for defects and breakage of nuts and bolts.

• Are measures being taken to lock nuts and bolts where
needed?

• Are plain washers being used in slots?

• Are the lengths of bolts appropriate?

• Are matching marks inscribed on nuts and bolts subject to
vibration?

• Are uniform bolts, nuts and washers being used in the
same mounting locations?

• Are jigs and tools, such as spanners, organized in easy-
to-use positions (indicated positions)?

• Are means being devised and improvements being made
to make nuts and bolts in frequently used locations easy
to attach and remove?

• Have tentative inspection standards been prepared?

• Have improvements been made to reduce the number of
inspection items?

• Have improvements been made to make inspection
easier?

• Are the inspection methods and period appropriate?

• Are means being devised so that inspection is performed
steadily, and without omissions?

© JIPM

Procedure for Implementing Step 5 7•2 9-1

Procedure for Implementing Step 5: "Autonomous Inspection"

In Step 5, we learn about integrated equipment, and enable the maintenance of equipment
"as it should be" within the standard time allotted per day.

Preparation for ♦ Autonomous study
autonomous 1. Selection of a pilot study model machine: From the viewpoint of "my machine!"
inspection 2. Selection of study theme (study of functional conditions from the viewpoint of preventing failures and defects)

3. Collection of reference materials and creation of study aids (one-point lessons and "don'ts")

♦ Autonomous inspection
1. Division of maintenance work functions

2. Creation of an annual maintenance calendar and maintenance levels (inspection, examination, replacement and
disassembly)

(First, list all necessary items without considering the division of maintenance roles)

3. Consolidation and reevaluation of the tentative standards created in Steps 3 and 4 (specialized maintenance
personnel should take a leading role).

4. Identification of the control conditions of the "system causing the problem," based on past failures and the log of
defects.

5. If cleaning, oiling and retightening work does not fit in the daily standard time allotted, identify areas that can be
improved, and identify ways for increasing the level of visual management of management key points.

Implementa- ♦ Autonomous study
tion of
1. Sharing of knowledge about equipment functions ("motion" and "function") through study materials.
autonomous 2. Understanding weak points from the viewpoint of "motion" and "function" and setting inspection points.
inspection ♦ Autonomous inspection

1. Organization and consolidation of inspection items, inspection period, time requirements and division of roles

2. Creation of autonomous inspection standards → Including standardization of the prevention of problems

3. Operation and trial inspection based on autonomous inspection standards→ Reevaluation of standards

4. Improving efficiency in cases where cleaning, inspection, oiling and retightening work will not fit within the
standard time allotted per day

5. Improving inspection efficiency for management key points

Implementation of visual management

6. Improving the accuracy of criteria used to identify problems

7. Creation, utilization and reevaluation of the annual maintenance calendar and checksheets

Measurement ♦ Autonomous study: Test of level of understanding, meetings to announce results, etc.
of effective-
ness ♦ Autonomous inspection
1. Changes in the time needed for cleaning, inspection, oiling and retightening

2. Changes in the inspection time for management key points (functional parts)

3. Understanding the difference between the daily standard time and the actual required time (making ways to
improve performance tangible)

4. Evaluating the reliability of criteria for determining problems (trend management) --- "motion" and "function"

Circle ♦ Autonomous study: Sharing knowledge about the man-machine weak points (motion and function)
meetings ♦ Autonomous inspection
1. Organizing issues related to improving the efficiency of cleaning and inspection, and formulation of ideas to make

improvements
2. Develop proposals to increase the accuracy of the criteria for judging problems (basic conditions and conditions used)
3. Changing over people's thinking from "management by praying for divine intervention" to "management by action."
4. Sharing the preparation and summarization of autonomous inspection standards

Preventing ♦ Autonomous study→ Check the degree to which the material studied is reflected in the autonomous inspection
future standards
recurrence
♦ Autonomous inspection
1. Creation of autonomous inspection standards, and training of behavior

Establishment of activities to prevent problems
2. Verification of the level of implementation of the annual maintenance calendar and checksheets

3. "Disclosure and demonstration" of cleaning, oiling and retightening → Measurement of time and verification of
compliance

4. Implementation of autonomous diagnoses → Tentative step diagnoses → Final step diagnoses

Advance to Step 5 Tentative diagnosis of all equipment Advance after passing the diagnosis
Final diagnosis on a circle unit basis

© JIPM

Planning Chart for

Purpose Date

Activity item
1 Reevaluation of standards

2 Correction of problems in the standards

3 Creation of final standards

4 Creation of an autonomous maintenance
calendar

5 Implementation of autonomous maintenance

6 Autonomous diagnoses

7 Top Executive diagnoses

r Step 5 Activities

Department Section Circle Planning Chart for Step 5 Activities

7•2

9-2

© JIPM

List for Evaluation of Cleaning, I

Assigned Name of Date Date Circ
area standard created revised
Aspe
Part Location Time Period

Inspection and Oiling Standards List for Evaluation of Cleaning,
Inspection and Oiling Standards
cle Section Department

ect of improvement Revision

d Division Method Other Description,
of roles time, etc.

7•2

9-3

© JIPM

Cleaning, Inspection and O

Area assigned: Manufacturing Section

Machine name: NC Bender, No. 7 Control No.: NF-01

In order to "take care of my equipment on my own," I will clean my equipment on my own as fol

Illustration No. Classi- Cleaning, oiling and Criteria
fication inspection location

1 Inspec- Main power supply Beeps
tion

2 Inspec- Hydraulic pump ON Spinning moto
tion emits sound

3 Inspec- Hydraulic main 40kgf/cm2
tion pressure

4 Inspec- Operation panel Check manua
tion switch

5 Inspec- NC side air 4kgf/cm2
tion pressure

6 Inspec- Supply side air 5kgf/cm2
tion pressure

7 Inspec- 3-point set vicinity No air leaking
tion

Inspec- Emergency stop by Machine stop
8 tion means of safety Indicator lamp
door
lights (red)

Inspec- Work verification Verify that
9 tion sensor lamp lights on
amplifier unit

10 Inspec- Verify operation of No abnormal
tion bender drive unit motion

11 Inspec- Verification of No abnormal

tion compaction operation motion

12 Inspec- Verification of No abnormal
tion pressure operation motion

13 Inspec- Verification of chuck No abnormal
tion unit operation motion

14 Inspec- Verification of touch No abnormal
tion sensor unit operation motion

Inspec- Verification of No abnormal
15 tion carriage vertical motion

operation

Oiling Standards Example of Reevaluating General Inspection
Standards: {1} Before Improvement
Date created: __/__/__

2, __ Circle Section Subsection Group Created
Manager Manager Manager by

llows. Person in charge of cleaning the equipment

Method of Time Period Timespan for
Tools re- implementing

implementation used quired cleaning, inspection

Daily Weekly Monthly and oiling

Press the power Screen 10 sec. { Daily 08:30 -
key display

or Press hydraulic key Hearing 10 sec. { Daily 08:30 -

Check with Seeing 5 sec. { Daily 08:30 -
pressure ON Seeing 5 sec. { Daily 08:30 -
Seeing 25 sec. { Daily 08:30 -
al Check in manual
operation mode

Check with air ON

Check with air ON Seeing 5 sec. { Daily 08:30 -

g Check with air ON Seeing 3 sec. { Daily 08:30 -

ps Open door. Seeing 15 sec. { Daily 08:30 -
p Machine stops 3
10 sec. { Daily 08:30 -
sec. later.
10 sec. { When in operation
Inspect when Seeing 10 sec. { When in operation
n starting with a 10 sec. { When in operation
10 sec. { When in operation
dummy rod 10 sec. { When in operation
10 sec. { When in operation
Verify while in Seeing

continuous operation 7 • 2 9 - 4 - (1)

Verify while in Seeing

continuous operation

Verify while in Seeing

continuous operation

Verify while in Seeing

continuous operation

Verify while in Seeing

continuous operation

Verify while in Seeing

continuous operation

© JIPM

Cleaning, Inspection and O

Area assigned: Manufacturing Section

Machine name: NC Bender, No. 7 Control No.: NF-01

In order to "take care of my equipment on my own," I will clean my equipment on my own as fol

Illustration No. Classi- Cleaning, oiling Criteria
fication and inspection
location

Inspec- Oil temperature Normal
1 tion gauge temperature: 3
- 50 deg.

2 Inspec- Oil quantity gauge H-L range
tion

Clean- Feed chain No aluminum
3 ing powder, sagging
or depletion of o

Oiling Feed chain No foreign
4 matter or
depletion of oil

5 Oiling 3-point set oil H-L range
quantity

6 Clean- Exhaust cleaner No waste oil in
ing the pan

Clean- Supply arm hand No aluminum
7 ing powder or
foreign matter

8 Oiling Supply arm hand No depletion of
oil

Clean- Spline shaft No rust or flaws
9 ing

10 Oiling Spline shaft No depletion of
oil

Clean- Ball screw No waste on
11 ing screw unit or
wiper unit

12 Oiling Ball screw No depletion of
oil

13 Inspec- Sensor for detecting No looseness o
tion presence of work locking screws

14 Inspec- Hopper unit sensor No looseness o
tion locking screws

Oiling Standards Example of Reevaluating General Inspection
Standards: {2} After Improvement
Date created: __/__/__

2, __ Circle Section Subsection Group Created
Manager Manager Manager by

llows. Person in charge of cleaning the equipment

Time Timespan for

Method of Tools re- Period implementing
implementation used
quired cleaning,

inspection

Daily Weekly Monthly and oiling

Verify after 1 hour of Seeing 3 sec. { Daily 17:00 -
30 operation

Verify after 1 hour of Seeing 3 sec. { (Thursday)
operation 20 sec. { (Thursday)

Wipe off dirt Waste 20 sec. { (Thursday)
g cloth
oil

Pour oil up to inside Oil type

the links No. 13

Pour up to H Oil type 20 sec. { (Thursday)
n Recover waste oil No. 1 { (Thursday)

20 sec.

Wipe dirt away Waste 20 sec. { (Thursday)
cloth

f Spray evenly on Oil type 20 sec. { (Thursday)
sliding surfaces No. 10 { (Thursday)
{ (Thursday) 7 • 2 9 - 4 - (2)
s Wipe dirt away Waste { (Thursday)
cloth
f Spray entire shaft
unit Oil type
Wipe dirt away No. 13

Waste
cloth

f Spray entire screw Oil type { (Thursday)
unit No. 13
Seeing { Inspect during
of Inspect during cleaning
s cleaning Seeing
{ Inspect during
of Inspect during cleaning
s cleaning
© JIPM

Equipment Mainte

Example of Reevaluating Equipment Maintenance Standards __ Inc. __ Plant __
Equipment No.: PHO4 PHO4
Equipment name: BF3 Target unit: Rolling former

Target part Inspection items Inspection method Criteria

Power chuck (1) Wear in master jaw slide unit (3 Use specialized measuring tools based All 3 master jaws with
Revised units/set) on separate attachment and inspection
11/1/19__ standards

Supplemented (2) Wear in the chuck pawl for attaching ↑ All 3 chuck pawls with
7/13/19__ the roller roll (3 units/set)

(3) Wear in the shaft for attaching the ↑ All 3 shafts within 0.0
roller roll (3 Use a blade micrometer

units/set)

(4) Deformation of the chuck pawl shaft Measure the internal diameter of the All 3 chuck pawls with

hole (3 units/set) hole with a cylinder gauge

(5) Play when the spindle is rotating Use a dial gauge to measure the play Radial direction: With

in the radial and thrust directions Thrust direction: With

(6) End stopper for setting roll diameter Use a dial gauge to measure circularity ±0.05 mm
when the chuck is fully open

(7) Looseness or breakage of the end Visual inspection and retightening No looseness or brea
stopper attaching bolts (3 units/set)

(8) Looseness or breakage of the roller Visual inspection and retightening No looseness or brea
roll attaching bolts (3 units/set)

(9) Looseness or breakage of the power Visual inspection and retightening No looseness or brea
chuck attaching bolts

(10) Oiling condition of the master jaw Visual inspection (oil once a No loss of oil film

month)

Roller unit (11) Oil leaking from the hydraulic piping Visual inspection No oil leakage
motor (1) Operating condition Visual inspection and inspection for No abnormal noise o
odors and noise
(2) Looseness of attaching base Retighten using specialized tools No looseness or brea
(3) Loose or missing V-pulley keys Visually check matching marks No misalignment of o

(4) Wear in the V-pulley groove Visual inspection No cracks or light in t
(5) Wear in the V-belt Visual inspection No twisting or slipping
operation
(6) Tension of the V-belt Verify the matching marks of the No misalignment of m
tension bolts
Visually check operation No twisting or slipping

enance Standards Example of Reevaluating Equipment
Maintenance Standards
_ Maintenance Section Date of last revision: __/__/__
Date created: __/__/__

a Period Method Person-in-charge
hin 0.18 mm 1/3M
In When Autonomous Specialized
operation stopped maintenance maintenance

{ {

hin 0.10 mm 1/3M { {
{ {
05 mm Check visually at setup { { {
time { {
{ { {
Measure once every 3 { {
months { { {
{ {
hin 8.2 mm dia. 1/3M { { {
{ { {
hin 0.02 mm 1/6M { {
hin 0.02 mm 1/3M {
{ {
akage At start-up { {
{
akage At start-up

akage At start-up

or odor Oil once a month {
Visual inspection once {

every 3 months {
1/D {
{
During operation

akage of bolts 1/M 7•2
or missing keys Once a day when
starting operation
the groove
g during 1/3M
1/D

matching marks 1/D 9-5

g of the V-belt

© JIPM

List for Identification and Co

Autonomous Maintenance Step 5 Date D
Classification of standard created
Problem point
No. Cleaning Inspec- Oiling Mainte- (What, who and how)
tion nance

orrection of Problem Points List for Identification and
Correction of Problem Points
Department Section Circle

Nature of improvement Effectiveness
(What will be done?) (What will change and how

will it change?)

7•2

9-6

© JIPM