JIPM-TPM.Sample-Forms-Editing-2

Final Cleaning, Inspection and Oiling Standards Machine

Date created: __/__/__ Assigned area: Circle Section
No. Standard
Location Implemented
by

e name: Section Subsection Circle Created Final Cleaning, Inspection and Oiling
Method Standards
Manager Manager Leader by

Department Time Clarification Procedure
Period of purpose No.

Day Week Month

7•2

9-7

© JIPM

19__ Mac

__________ Department JishuHozen(AM)

_____________ Section Annual Maintenance Calendar

Part Maintenance classification Details of maintenance Part name MTBF

chine name: Engineering Division Manufacturing Division Annual Maintenance Calendar

Subsection Section Subsection Person-in-

Manager Manager Manager Manager charge

Date of installation 1 2 3 4 5 6 7 8 9 10 11 12

7•2

9-8

© JIPM

__/__ M

Department Autonomous Maintenance
Calendar

Section (Month/Week/Day)

Part Classifica- Details of During While Person- 1 2 3 456 78 9 10 11
tion maintenance operation stopped in-charge

Machine name: Engineering Division Manufacturing Division Maintenance Calendar (Monthly)

Section Subsection Section Subsection Person-in-
Manager Manager Manager Manager charge

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

7•2

9-9

© JIPM

__/__ Checksheet for Auton
Inspection
Assigned area ______ Circle ________ Section
________________ Department (Cleaning, Oiling and In

Machine name

Classification No. Item Standard No. Standard Method 1 2 3 4 5 6 7 8 9 10 11

Remarks

nomous Period Section Subsection Person-in- Checksheet for Autonomous
Manager Manager charge Inspection

Daily Weekly Monthly

nspection)

12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

7•2

9 - 10

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Checksheet for Autonomous Inspection

Skills Circle Section

Evaluation A. E.
item B. F.
C. G.
D. H.
E. I.

Name Name Name

Name Name Name

Section Subsection Circle Checksheet for Autonomous
Manager Manager Leader Inspection Skills

Department

Evaluation Level 1: Understands it intellectually
level Level 2: Can perform autonomous inspection to some extent
Level 3: Can perform autonomous inspection
with confidence
Level 4: Can teach others

Name Name

Name Name

7•2

9 - 11

© JIPM

Step 5 Diagnosis Sheet 7•2 9 - 12

Subsection Section TPM Autonomous Maintenance Step 5
Target equipment: Department Autonomous Inspection Diagnosis Sheet

Diagnosis points Evaluation points

Are the steps up until now being 65 4 3 2 1
maintained?
Status of Improved re- Improved Maintained as Passably Below the level Level has
follow-up for Have improvements been made for when passed when passed regressed
problem points identified in previous markably since somewhat since
Steps 1-4 diagnoses? 4 1
(Comments) passing steps passing steps 3 2
Details of autonomous Passably No im-
inspection 65 Could do better Not yet provement

Purpose All have been Most have been /12
Through general
inspections, to steadily improved improved
maintain conditions
Diagnosis points Evaluation points
that restore
deterioration Are necessary inspection items 43 2 1
being omitted "for reasons of Not yet
Improved the inability?" No blind spots No omissions for Could do better
efficiency of cleaning, the most part 1
inspection and oiling Inspection Are inspection items specific to Not included
items the equipment being included? 432
through devising 1
means for visual Included without Included for the Not yet Not coordinated

inspection exception most part /12

Have periodic inspections been 4 3 2
coordinated with the Engineering Could do better Not yet
Section? Appropriate
coordination

(Comments)

Diagnosis points Evaluation points

In cases where there are many 4 3 2 1
inspection items, are they Divided Not yet Indeterminate
divided up to make Appropriately
implementation easier? divided 2 1
Not yet Not possible
Ease of Are standards set so that the 43
inspection period of inspection can be Can be observed Could do better 2 1
Not yet No means
observed?
2 devised
Are means devised for "visual" 4 3 Not yet
management to make inspection Could do better 1
easier to perform? Means devised 2 Not sequenced
for visual Not yet
inspection 1
Completely
Is the sequence of inspections 43 impossible
arranged to make inspections
easy to perform? Appropriately For the most part /20
sequenced

Can be performed in the allotted 4 3

time? Can be For the most part

performed within

the allotted time

(Comments)

Diagnosis points Evaluation points

Quality With regard to predetermined 4 3 2 1
related items, Not yet Not incorporated
items Well Incorporated for
(a) Is inspection incorporated incorporated the most part
for quality (Q)?
4 3 2 1
(b) Is the check for weighing Thorough Passably Could do better Poor
equipment, measuring
equipment, detection
equipment and
misoperation prevention
equipment satisfactory?

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

Diagnosis points Evaluation points

(c) Are proper accuracy checks 4 3 2 1
of equipment and tools for Well defined Defined Passably Not defined
checking processes being
carried out? /12

(Comments)

Reevaluate the role Diagnosis points Evaluation points
of equipment and the
Are inspections being carried out 4 3 2 1
role of people, and in accordance with inspection Could do better
clarify what an standards, and are records being Thorough inspection Inspections and record No record
kept? and record keeping keeping are being keeping
abnormal condition is
performed for the most
Make improvements
so that equipment Implement- Are improvements being made 4 part 2 1
has good ation for problem points identified as a Could do better No im-provement
operationality Thoroughly 3
status of result of inspections? improved Improved for the
inspections
most part

Are areas of deterioration being 4 321
reliably identified and handled as
a result of inspection cleaning? Reliably Identified for the Could do better Not yet started
identified most part

(Comments) /12

Diagnosis points Evaluation points

To devise means for raising the 43 2 1
Skill of level of inspection skills, Not understood
inspection (a)Are the weak points of Well understood Understood for Understood
the most part vaguely 1
inspection skills understood? Not yet started
(b)Are there plans for that 432
/8
training and education? Plans are clear Drafting of plans Drafting of plans

(Comments) in progress scheduled

Status of Diagnosis points Evaluation points
autonomous
maintenance Are the number of meetings, time and level 4 3 2 1
of participation in TPM group activities Satisfactory Normal Could be better Poor
activities satisfactory?
3 2 1
Purpose Is it understood why inspections must be 4 Understood for Understood Not understood
performed? the most part
To work toward an Clearly vaguely 1
autonomous understood 3 2 Not understood
Understood
management system Is the importance of raising one's own level 4 Not yet 1
through group 3 2 Not yet started
activities of inspection skills understood? Well understood Drafting of plan
Drafting of plan 1
Is there a plan to reevaluate and revise 4 in progress scheduled Not understood
3 2
standards based on data? Plan completed Not yet 1
Understood for Not defined
Do all personnel understand that this Step is 4 the most part 2
the overall wind-up of autonomous Understood Not yet /24
inspection? 3
4 Defined
Is the method for checking whether inspection Well defined
standards are being observed defined?

(Comments)

© JIPM

Purpose Planning Chart for

Activity item Circlet
1 Follow-up on Steps 1-5
2 Order and arrangement Date
3 Correction of problem points
4 Autonomous diagnosis
5 Top Executive Diagnosis

Planning Chart for Step 6 Activities 7•2 10 - 1

Departmen © JIPM

r Step 6 Activities
Section

Illumination [Symbol] - R Con

Lamp power
supply voltage

N
Seal of
approval

Autonomous Inspection Control 7•2 10 - 2
Chart x[bar]-R

ntrol Chart for Machine No. __

© JIPM

Flowchart of Measures for Equipment 7•2 10 - 3
Abnormalities

Flowchart of Measures for Equipment Problems

Manufacturing Division Engineering Department Manufacturer

Problem occurs Inspection
Inspection
Can be
restored in No
one's own Inspection
division?
No

Can be restored
in one's own
division?

Yes
Restore

Yes Restore
Restore

• Failure analysis sheet
• Maintenance record

Issue

© JIPM

Diagram of Layout for Storage of Material

Circlet

Classification Layout Article Storage quantity Person responsible
No.
Max Min for control

Diagram of Layout for Storage of Materials, 7•2 10 - 4
Products and Work-in-Progress

Departmen © JIPM

ls, Products and Work-in-Progress Section

e Layout diagram

Diagram of Layout for St

Classification Layout . Article Usage Circle
No
Qty. Person respo
for contro

torage of Jigs and Tools Diagram of Layout for Storage of
Jigs and Tools
Section Department
Layout diagram
onsible
ol

Standard for placement (illustration or photo)

7•2

10 - 5

© JIPM

Diagram of Layout for Storage of Spare Parts, Fixt

Classification Layout Article Storage quantity Circle
No. Max Min
Person respon
for control

Diagram of Layout for Storage of 7•2 10 - 6
Spare Parts, Fixtures and Others

Department © JIPM

tures and Others Section
Layout diagram

nsible
l

- 7•2 10 - 7

Textbooks for Operation Skills

Example of Textbooks for Operation Skills

© JIPM

Evaluation Table fo

Circle

Main Work Work item Name
Check date
classification classification

Evaluation standard 12 Level 1: Understood Level 2: Can perfo
34 intellectually to some e

or Operation Skills Department Evaluation Table for Operation Skills

Section

7•2

orm operation Level 3: Can perform operation Level 4: Can teach 10 - 8

extent with confidence others

© JIPM

Autonomous List for Identification and Im
Maintenance Step 6
Problem Points
No. Classification
Strain Variance Losses Circle

Problem point Cause
(What, where and how?) (Why did this happen?

mprovement of List of Corrections for Problem Points

Section Department

Nature of improvement Effectiveness

?) (What will be done?) (What will change and how will it change?)

7•2

10 - 9

© JIPM

Step 6 Diagnosis Sheet 7•2 10 - 10

Subsection Section TPM Autonomous Maintenance Step 6
Target equipment: Department Order and Arrangement Diagnosis Sheet

Diagnosis points Evaluation points

Are the conditions at the time of passing previous 32 1 0
steps being maintained? Passably Below the level
Improved since Maintained as when when passed
Have improvements and measures been taken for 1
Maintenance and control items cited at previous diagnoses? passing steps passed Low rate of 0
activities implementation No improvement
Is autonomous maintenance being steadily 32
Status of follow-up on implemented, and are standards being reevaluated 2 0
Steps 1-5 as needed? All have been Improved for the Inadequate Problems with
implementation
Order and arrangement Has the maintenance (cleaning, oiling and improved or are most part maintaining
"Equipment" retightening) of basic conditions been established? scheduled to be 1 autonomous
Could do better maintenance
Make firm decisions and Do the 5S of workplace improve? improved
steadily observe them 1 0
(Comments) 43 Could do better Still inadequate
Inspection of
equipment Steadily Reevaluation could 0
accuracy implemented and be better Still inadequate

Order and arrangement thoroughly /16
"Things" established

Are both quality and 32
quantity "as they
should be?" Established and Standards are

maintained in good being observed for

condition the most part

31

Extremely good Passably

Diagnosis points Evaluation points

Are checksheets being used, and is inspection work 3 2 1 0
Could do better Inadequately
being carried out steadily? Inspection work is Being implemented
0
well understood Items are not
understood
Are quality control items incorporated in the 3 2 1
inspection items, and does this lead to a reduction in Incorporated 0
defects? Leads to good Items are Inadequately
results understood but not
0
incorporated Not thoroughly
implemented
Are equipment problems handled speedily and 3 2 1
reliably? Handled reliably Passably Could do better 0
Not making
Is visual management thoroughly implemented, and 4 3 2
progress
have means been devised so that anyone can Thoroughly imple- Can be visually Cannot be 0
determine visually whether there is a problem? mented, and understood without
anyone can determined for the Still inadequate
determine problems most part explanation
/19
Are the number of inspection items being reduced, 3 2 1
and is the introduction of predictive maintenance
making progress? Making good Making partial Under
progress progress consideration

Are standards set for routine checking of detection 3 2 1
Could do better
and control equipment, and are their functions being There are Implemented in
accordance with
verified? standards and they standards for the

are firmly most part

established

(Comments)

Diagnosis points Evaluation points

Are the storage location and quantity of materials, 3 2 1 0
work-in-progress, products, defective products and Properly defined Some parts need to Mixed up
indirect materials clear? Defined for the
3 most part be redone 0
Are means being devised for the storage location Means are being Inadequately
and method of storage of jigs and tools, and are they 2 12
managed visually? devised and Passably
management is Management is
Are measuring instruments being stored so that they satisfactory
are easy to use and so that their accuracy can be satisfactory
maintained? 3 2 1 0
Storage location is
Properly stored Stored in a Instruments are
predetermined determined dirtied with waste,
Are means being devised for the storage location 3
and method of storage for oiling equipment, and is location 1 oil, etc.
the equipment managed visually? Means are being Passably
devised and 2 0
Is the storage location of machine consumables and
specific spare parts clarified, and are the point and management is Management is Inadequately
quantity decided?ordering satisfactory satisfactory

3 2 1 0
Inadequately
Properly decided Decided for the Some parts need to
most part be redone

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

Diagnosis points Evaluation points
Are things that are used infrequently managed
- Continued - centrally in one location? 3 21 0
Inadequately
Thorough visual Are things in a state that allow them to function Thoroughly Basically Some parts remain
management adequately? managed centralized to be centralized 0
Inadequately
Order and arrangement (Comments) 4 32
"Personnel" /22
In good condition Passable condition Could do better
Are the operator's without any
duties clearlydefined,
and are those duties breakage or dirt

being carried out? Diagnosis points Evaluation points

Thorough Are the various standards being reevaluated and 3 2 1 0
standardization properly ordered? Nearly completed Still being Will start from now
Ordered and in reevaluated
Group activities operation on
1 0
Are all members Have correct operation procedures, work 3 2 Working on it Not created
of the group actively requirements for handling, and standards for work
been created? Have been created Have been created 1 0
participating and and are being for the most part Planning in Not yet
are results being observed
progress 0
obtained? Are education and training being conducted for 3 2 1 Not yet
priority items related to operation procedures and Plan is completed
quality, and are skills being evaluated? Systematically Could do better 0
carried out Inadequately
1
Is work being performed according to standards, 3 2 Could do better 0
and is the work going well? Without difficulty Inadequately
Good for the most 1
part Partially not yet 0
Inadequately
When failures or quality defects occur, is each case 4 3 decided
1 /22
analyzed one at a time and are efforts made to Properly analyzed Generally analyzed
Could do better
prevent recurrence?

Are the methods for handling problems decided, and 3 2

are they observed? Thoroughly decided Generally
satisfactory
and observed

Are records being properly kept, and are they 3 2
organized and stored?
Properly Generally
implemented satisfactory

(Comments)

Diagnosis points Evaluation points

Looking at the activities board, are the activity 3 2 1 0
details and results, prevention of future recurrence Not yet linked
of problems, and future plans properly linked? Contents of Basically Contents are
activities can be understood unclear
seen at a glance

Is the focus of improvement set as a group, and are 3 2 10

all group members involved? All group members Focus is set and There is a focus but The focus is unclear
efforts are efforts are
are involved and underway inadequate

results are being

obtained

Are meetings lively and conducted as planned? 3 2 1 0

Five or more times Three or more Two or fewer times Meetings hardly
held at all
a month, and very times a month, and a month, and could

lively lively do better

Based on the concept of "learning from failures and 3 2 1 0
quality defects," are one-point lessons being written Extremely good Good Could do better Not yet
up and are countermeasures being taken?

Are improvement suggestions being actively 3 2 1 0

submitted, and are all members reaching their goals Six or more Four or more Two or more Under 2 sugges-
and improving their performance?
sugges- suggestions/person suggestions/person tions/person-month,

tions/person-month, -month, and -month, and could and inadequate

and all members satisfactory activity do better activity

reaching their goals

Is daily management established in order to raise 3 2 1 0
production efficiency? Inadequately
Daily management Handling of this is Awareness of daily
is established and slightly weak management is
insufficient
satisfactory

Do all personnel understand the meaning of 5S, and 3 2 1 0
Good Could do better Inadequately
is this apparent in their behavior? Extremely good

(Comments) /21

© JIPM

JIPM - TPM® 600 Forms Manual
Sample Formats for the12 Steps of TPM

7 3 Keikaku Hozen (Planned Maintenance)

© JIPM

7 3 Planned Maintenance
Overview of Planned Maintenance Activities

I. Activities to Enhance Maintenance Technology and Skills
Activities to Extend Equipment MTBF
Activities to Shorten Equipment MTTR

II. Activities to Efficiently Promote Maintenance1. Maintenance Work Plan and
Management
1. Guidance and Support Activities for Autonomous
Maintenance2. Maintenance Information
Management
2. 7 Step Activities for Planned Maintenance
3. Corrective Maintenance Activities3. Maintenance Spare Parts Manage-
4. MP Activities Autonomous Maintenancement and Lubrication Management
5. Research on Predictive Maintenance
4. Maintenance Cost Management
Reduction of Inputs
5. Enhancing Maintenance
Technology and Skills

Improvement of Output Establishment of a Planned
Zero Failures and Defects Maintenance System

© JIPM

7 3 Planned Maintenance

1. Support and Guidance for Autonomous Maintenance Activities

(Autonomous (Planned Red Tag Removal List
Maintenance) Maintenance) 1 and Red Tag Removal
Support for Red (1)(2)
Step 1 Tag Strategy Plan

Step 2 2 Red Tag Improvement
Sheet Removal Plan
Step 3
Step 4 Countermeasures for
Generating Sources
Support for Eliminating
the 4 Evils (Dirt, Rust,
Heat and Vibration)

Maintenance of Visual
Management Indication
of Level, Oil Type, etc.

Support for Cleaning and
Oiling Standard Strategy

Education for Leaders on
General Inspection

Step 5 Intermediate Education
Step 6 on Maintenance Skills

© JIPM

7 3 Planned Maintenance

Implementation of Planned Maintenance Phase

2. (Phase 1)
Evaluation of Equipment and Understanding Current Conditions

Creation and Maintenance of an (1) 1. Equipment Control Ledger
Equipment Ledger

Creation and Implementation of an 2. Evaluation Chart for Ranking
Equipment Evaluation Standard Equipment

1) Creation of an Evaluation 3. Equipment Rank Display
Standard

2) Ranking (2)

Selecting PM Equipment (3)

Understanding Current 4. Equipment Maintenance Record
Conditions (Log)

Equipment Maintenance 5. MTBF
Record (4)
MTBF (5) 6. Equipment Current Conditions
Equipment Current Checklist
Conditions Checklist (36)
Frequency and Intensity (7) 7. Equipment Failure Frequency
Process Capability Evaluation Table
Calculation Table (8)
MTTR (9)
Maintenance Expenses

8. Process Capability Evaluation
Table

9. Equipment Repair Time and
Frequency Evaluation Table

Set Maintenance Goals

(To Phase 2)

© JIPM

7 3 Planned Maintenance

Implementation of Planned Maintenance Phase

3. (Phase 2)
Restoration of Deterioration and Improvement of Weak Points

Restoration of Deterioration and (1)(2)(3) 1. Structural and Functional
Maintenance of Basic Conditions Diagram

2. Maintenance Work Standards

3. Failure Analysis Sheet

Improvements to Eliminate the 4. Sporadic Failure Report
Environment of Forced Deterioration
(4)(5) Component Function Analysis
Countermeasures to Prevent Sheet
Recurrence of Critical Failures and 5.
Similar Failures

Improvement of Weak Points and (6)(7)(8) 6. PM Analysis Sheet
Individual Improvement for Extending (9)(10) 7. QM Analysis Sheet
Service Life (Corrective Maintenance)

8. Improvement Sheet

9. MP Information Sheet

10. Improvement Details Summary
Sheet

Making Anticipated Problems Tangible (11) 11. FMEA Chart
(FMEA)

Maintenance and Control (12) 12. One-Point Lesson Sheet

(To Phase 3)

© JIPM

7 3 Planned Maintenance

Implementation of Planned Maintenance Phase

4. (Phase 3)
Creation of an Information Management System

Construction of a Failure Data (1) 1. Failure Data Management
Management System System Flowchart

Construction of an Equipment (2)(3) 2. Equipment Maintenance
Maintenance Management System (4)(5) Management System Flowchart

* Machine Log Management 3. Equipment Maintenance Report
* Maintenance Management
* Inspection Plan

4. Equipment Inspection Schedule

Construction of an Equipment Budget Maintenance Construction Work
Maintenance System Performance Table

5.

Spare Parts Management System (2)(6) 6. Spare Parts Management
(7)(8) System Flowchart

* Drawings and Documents 7. Inventory List
Management

8. Maintenance Parts Actual Usage
Record

(To Phase 4)

© JIPM

7 3 Planned Maintenance

Implementation of Planned Maintenance Phase

5. (Phase 4)
Creation of a Periodic Maintenance System

Activities to Prepare for Periodic (1) 1. Periodic Maintenance Work
Maintenance Standard

Management of Spare Machines, Spare 2. Periodic Maintenance Work
Parts, Measuring Tools, Lubrication, System Flowchart
Drawings and Technical Documents

Flowcharting the Periodic Maintenance (2)
Work System

Selection of Target Equipment and (3) 3. Flowchart for Selecting Target
Locations Equipment and Locations

Formulation of a Maintenance Plan (4) 4. Periodic Maintenance Calendar

Creation and Maintenance of Standards (5)(6)(7)(8) 5. Material Selection Standard

(9)(10)(11)(12)

6. Construction Cost Estimation
Standard

7. Spare Parts Management
Standard

8. Lubrication Oil (1) Oil Changing Period
Changing and Chart

(2) Oil Replenishment

Supply Management and Supply Period
Chart

9. Lubricant Usage Classification
Table

(1) Lubrication

10. Lubrication Inspection Standard
Inspection Standard (2) Lubrication

Inspection Items

Table

(3) Lubrication Oil

Maintenance Sheet

11. Work Safety Standard

Improving the Efficiency of Periodic (13)
Maintenance, and Strengthening
Management of Outsourced 12. Network Process Table
Construction Work
13. Periodic Maintenance Report
(To Phase 5)

© JIPM

7 3 Planned Maintenance

Implementation of Planned Maintenance Phase

6. (Phase 5)
Creation of a Predictive Maintenance System

Introduction of Equipment Diagnostic (1) 1. Equipment Diagnostic Manual
Technology
(1) Positioning of Equipment Diagnostic
1) Training of Engineers Technology
2) Introduction of Diagnostic Equipment
(2) Principle Equipment Diagnostic
Creation of a Predictive Maintenance Technology and Its Main Functions
Work System Flowchart
(3) Purpose and Aims of Equipment
Diagnostic Technology, and an
Overview of the Study Course

Selection of Equipment and Locations 2. Predictive Maintenance Selection
Targeted for Predictive Maintenance Flowchart

Predictive Maintenance Selection (2) 3. List of Locations and Diagnostic
Flowchart (3) Equipment
List of Locations and Diagnostic
Equipment

Practical Training on Predictive (4) 4. Equipment Diagnostic Trend
Maintenance Management Sheet

(5) Inspection Report for Predictive
Maintenance
Example of Diagnosing Pump Vibration 5. (Example of Diagnosing Pump
Vibration)

Development of Diagnostic Equipment
and Diagnostic Technology

(To Phase 6)

© JIPM

7 3 Planned Maintenance

Implementation of Planned Maintenance Phase

7. (Phase 6)
Evaluation of Planned Maintenance

Evaluation of the Planned Maintenance 1. List of Maintenance Evaluation
System Indices

List of Maintenance Evaluation (1) 2. Graph of Evaluation Indices

Indices (2)

Graph of Evaluation Indices

Evaluation of Reliability Improvement

1) Number of Failures and Minor (3) 3. Details of Measurement and
Stoppages (3) Evaluation
(3)
2) MTBF
3) Frequency of Failures

Evaluation of Improvement in
Maintainability

1) Periodic Maintenance Rate (3)
2) Preventive Maintenance Rate (3)
3) MTTR (3)

Evaluation of Cost Reductions

1) Reduction in Maintenance (3)
Costs (3)

2) Improvement in Usage
Classification of Maintenance
Costs

(To Phase7)

© JIPM

7 3 Planned Maintenance

Implementation of Planned Maintenance Phase

8. (Phase 7)
Establishment of Planned Maintenance

Improvement of CBM

Establishment and Improvement of a
Maintenance System

Reduction of Maintenance Total Costs

© JIPM

73 Planned Maintenance

9. Failure Analysis Flow

Creation of a Failure Record

Collection and Organization of Data

Failure Record

Organizing the Function, Construction
and Proper Usage of Equipment

Investigation of Equipment Characteristics

Structural and Functional Diagram
One-Point Lesson
Inspection Standard
Work Standard

Pursuit and Analysis of Causes, and
Listing Inspection Items

Failure Analysis Sheet
Machining Point Analysis
Why-Why Analysis Sheet
FTA
FMEA
PM Analysis Sheet
Inspection of Actual Situation Based on
Inspection Items

QM Matrix
Component Function Analysis Sheet

Restoration of Problem Locations

Improvement Sheet
Improvement Details Summary Sheet

Draft of Countermeasures to Prevent
Recurrence

MP Information Sheet
Organization of Failure Analysis Sheets
and Creation of Inspection Standards

Evaluation Sheet for Implementation Rate of Countermeasures for Failures

MP Information Registration

© JIPM

Planning Chart: "Red Ta

Description Structure Construction

List Equipment Natural deterioration
name Forced deterioration
No. Other
1 51

10 15 20 25 30 ag Removal"

Countermeasures completed Equipment
n work implementation schedule
OS/P&I revision
Correction to completed drawing Deals with
Revision of inspection and examination standards
© JIPM Improvement case example sheet Month
MP information sheet
Tentative control chart for functional support
Improvement suggestion
Red tag removal

1-1 7•3 Red Tag Removal List and Red Tag
Removal Plan

Red Tag Improvement Sheet 7•3 1-2

Problem Discovery and Improvement Sheet

Promotion Section Subsection Department Group Created by
Office Manager Manager Promotion Manager
Discovery No. Improvement No.
Department Group/Circle __ Circle
Date discovered name

__:__ __/__/__

Equipment name __ conveyer Discovered by: __

State the problem (phenomenon): Water drips from the pan and pipes, dirtying the floor

Analysis of problem location Describe problem/improvement point (use photos and drawings to make it
easy to understand)
* Why did the problem occur?
(What are the main causes, aggravating causes Before Improvement
and hidden causes?)
(Record on a separate sheet of paper as needed.)

• The pan and PVC pipe are not in the
correct position, and water is dripping.
Further, the PVC pipe sticks out into the
passageway, interfering with traffic.

* What will happen if the problem is left as is? After improvement

(Equipment failure, product defects, quality
problems, etc.)

• Waste water will drip, making the floor
slippery

• Will become unable to perform cleaning
* Resulting estimated financial loss and down
time:

• Increase in the cleaning frequency and
cleaning time

Improvement of problem locations

* What will be improved and how will it be
improved?
• Will reattach pan
• Will eliminate waste water pipe
(will change the waste water route)

* Improvement cost and manhours

__ yen __ hr, __ persons

* Effect obtained by improvement
• Reduction in cleaning time: __ hr

• Drying of the floor prevents tipping of
loads

© JIPM

Equipment Management 7•3 2-1

Equipment Management Record

Asset No. Designed by Date Subsection/line name

Equipment name Date created Installation location

Model Purchased from

Drawing No. Purchase date

Purchase price (1,000 yen)

Periodic maintenance/modifications Main failure and repair

and improvements Amount Amount
(1,000 yen)
Date Location Details (in-house (1,000 yen) Date Location Details (in-house
manhours)
manhours)

© JIPM

Evaluation Chart for Ranking Equipment (Evaluation

Classification Evaluation Equipment nam
Evaluation points

1. Average level of operation 5421

Production 2. Availability of a spare machine or alternate 421

machine, and the ease of switchover

(PD) 3. Impact of a failure on other equipment 5421

4. Frequency of failure 421

5. Down time for repairing failures 421

Quality 6. Product fabrication process capability 5421
7. F Cost 421
(Q) 8. Total repair cost 421

Cost

(C)

Safety 9. Risk of a failure causing injury 5421
10. Risk of a failure causing pollution 5421
(SM)

Total points

Note Total evaluation

Integrated line: A=41-27 B=26-18 C=17-10
General equipment: A=45-29 B=28-19 C=18-10

n Table for Selecting Priority Equipment) Evaluation Chart for Ranking
Equipment
me
7•3
1
1 2-2
1
1
1
1
1
1
1
1

© JIPM

Equipment Ran

PM-A Rank Seal
PM-B rank seal

nk Display Equipment Rank Display

Example of usage 7•3
© JIPM
2-3

Monthly Equipment M

Details Equip Date Machine UT name UT Location Loca- Part name Maintenance Mainte- Functio- Phenomenon Details of
-ment of No. ST name tion performed nance nal classification pheno-menon
name work ST by type configu-
ration

External 0A309 _/_/_ Line 3 Adjustment 2R θ shaft Servo- Autonomous BM Drive Operation Cannot set
mainte- drive area motor maintenance Breaking problem home position
nance
1R Servo- Autonomous BM Drive Operation Cannot set UT
_/_/_ motor maintenance BM Breaking problem home position
Servo- Autonomous CBM2 Drive
Adjust- 0A309 _/_/_ Line 3 Adjustment 1R θ shaft motor maintenance CBM2 Breaking Operation Cannot set UT
ment Line 1 drive area One-way Autonomous CBM2 Rotation problem home position
External 0A309 _/_/_ clutch UT maintenance BM Sliding
mainte- Line 2 Examine 2R DM drive One-way Autonomous Wear Frequent
nance interlocking clutch UT maintenance BM Rotation measurement
One-way Autonomous Sliding malfunctions
_/_/_ Examine 2L DM drive clutch UT maintenance
interlocking Servo- Autonomous Rotation Wear Frequent
motor maintenance Sliding measurement
malfunctions
Servo- Autonomous Drive
_/_/_ Line 1 Examine 4L DM drive motor maintenance Breaking Wear Frequent
interlocking measurement
Drive malfunctions
Breaking
Adjust- 0A309 _/_/_ Line 3 Adjustment 3R θ shaft Center Poor motion
ment drive area misalignment

Positional
misalignment

External 0A309 _/_/_ Line 3 Adjustment 1R θ shaft Open Cannot set
mainte- Line 3 drive area circuit home position
nance
Adjust- 0A309 _/_/_ Adjustment 1R θ shaft Servo- Autonomous BM Drive Other Home
drive area motor maintenance BM Breaking becomes
ment Floating Autonomous BM misaligned a
chuck maintenance BM Manipu- little at a time
CBM2 lation of
_/_/_ Line 2 Adjustment 3R VP Autonomous work Center Frequent pitch
positionin maintenance Manipu- misalignment misinterlockin
g Floating Autonomous lation of g
chuck maintenance work Positional
One-way Autonomous Manipu- misalignment
clutch UT maintenance lation of
_/_/_ chuck work Center Frequent pitch
Rotation
Sliding misalignment misinterlockin
g
Positional
misalignment

External 0A309 _/_/_ Line 2 Adjustment 3R VP Fracture Frequent pitch
mainte- Line 1 Measure- positionin Breakage misinterlockin
nance g chuck g
ment
_/_/_ 2L DM drive Wear Abnormal
area transport

_/_/_ Examine 1L DM drive One-way Autonomous CBM2 Rotation Other Abnormal
interlocking area clutch UT maintenance Sliding transport of
Wear clutch lead-in
_/_/_ Line 2 Measure- 1L DM drive One-way Autonomous CBM2 Rotation
ment area clutch UT maintenance Sliding Wear Frequent
measurement
_/_/_ Line 1 Examine 2L DM drive One-way Autonomous CBM2 Rotation Wear malfunctions
interlocking area clutch UT maintenance Sliding
Wear Defective
_/_/_ 2R DM drive One-way Autonomous CBM2 Rotation Seizing discharge of
area clutch UT maintenance Sliding Galling quality products

_/_/_ 2L DM drive One-way Autonomous CBM2 Rotation Defective
area clutch UT maintenance Sliding discharge of
quality products
_/_/_ Measure- 2L DM drive Thrust Line TBM Rotation
ment area bearing maintenance Sliding Defective
discharge of
worker quality products
No drive from

DM