(§ 2-1/5)

§ 2. Daily Maintenance Checks

The manufacturing factories are constantly changing. Daily maintenance checks are
critical!
1. Purpose
1) To produce quality products, machining and other manufacturing equipment must be in good
condition.
2) To stabilize manufacturing quality, inspect equipment for abnormalities.
3) Prevent equipment failure and defects by detecting abnormalities in equipment and gauges.
* Key check point
• At the beginning of work, inspect manufacturing equipment for abnormalities. (Checking the
settings only is not sufficient. → Check measurements to make sure proper functioning.)
* Poorly controlled equipment
• Use of abnormal equipment for production → 100% defective

2. Scope
Equipment involved in production except test equipment. Periodic inspections are not within the scope of
daily maintenance checks.

3. Examples (Based on Past Defects)

1) A wire break occurred in the molding resin heater at NSS. Operators were monitoring the heater
temperature settings. However, they failed to detect the decrease in temperature reading
(measurement). Poor molding resin flow resulted in clearances between resin and case, water
ingress and a serious defect. The manager was checking the information shown on the check sheets
once every month, but failed to monitor the operators’ check methods on site. (Inappropriate check
methods)
2) A defect in equipment was detected during start-up inspection and was corrected. (A 0.5 MPa
decrease from the normal level occurred in air pressure measurement and the equipment was
adjusted.) This was reported to management. However, the manager failed to check the quality of
the products which had been produced on the previous day. This resulted in a large quantity of
defective items continuing to the next step. (Failure to take corrective action after the detection of an
abnormality)
3) Daily check sheets were completely filled out, which showed same air pressure gauge readings,
although the oily gauge was unreadable. The manager left checks entirely up to operators and failed
to monitor the check method. (Failure to perform checks)
4) After a long shutdown, the motion of a press tightening machine was less than optimal. Since the
hydraulic pressure was normal and no problem was detected during start-up inspection and first
piece checks, the operator continued operation. However, this resulted in loose press tightening.

4. Daily Maintenance Check Procedure

To improve checking efficiency, make gauge indications more visible and conduct precise checks
through review.
 See daily maintenance check supplementary information 1: Daily Maintenance Check Procedure.

For how to handle abnormalities detected, see § 10 “Abnormality Corrective Actions.”

5. Changes before and after Long Shutdown

A long shutdown such as during the summer vacation or the New Year holidays turns stationary
conditions to non-stationary changes, potentially causing unexpected defects. Prepare for the long
shutdown by making a list of control items. After the long shutdown, conduct process and quality checks.
 See daily maintenance check supplementary information 2: Check Items before and after Long
Shutdown.
 (§ 2-2/5)
Daily maintenance check supplementary information 1

Daily Maintenance Check Procedure

It is important for operators to understand the following to implement correct daily maintenance checks.
1. Check Sheet Preparation ( See daily maintenance check supplementary information 3: Daily
Maintenance Check Sheet and Example Preparation.)
1) Check item selection
• Select check items that have a substantial impact on quality and output (e.g., from operation
manuals and Quality Control process charts) and those intended to prevent recurrence of past
defects.
2) Specify when to check (at the beginning of work and during operation).
• Some items can be checked only when equipment is in operation.
3) Check frequency shall be once a day, week or month. Decide frequency according to the degree of
importance, degree of impact and frequency of use.
• Decide check frequency according to the degree of importance.
4) Specify criteria for check items to facilitate Judgment.
• Pass and fail criteria shall be easy to understand. (Use “4 to 6” instead of “5 ± 1.”)
5) Check measurements rather than settings. Measurements shall be filled in on check sheets.

2. Improve Checking Efficiency and Conduct Precise Checks through review

It is important to detect defects in equipment before defective occurs. Since it takes valuable time,
conduct efficient and precise checks to prevent defects.
1) Gauges
• Move or place gauges in positions easily visible to the checker.
• Make pass and fail ranges (marked in green and red) easily visible.
• Clean dusty or oily gauges. Provide flashlights for dark areas.
Examples

Easy to read locations Colored pass/fail ranges

(marked green and red)

2) Check sheets
• Arrange check items and equipment check points into the same sequence (indicate check item
numbers on equipment).
• Use a binder or the like to hold check sheets so that it is easy to fill them out.
• Place or store check sheets near the equipment to be checked.
• Checkers shall hold check sheets in such a manner that they can check each item without fail.
 (§ 2-3/5)
3) Use an orderly (efficient) check sequence (e.g., from top to bottom and right to left).

Examples

Gauges placed in a Gauges numbered in check

row sequence

3. Checks by Executive/Manager
Looking at actual checking procedures is more important than investigating daily maintenance check
records.
1) Witness checks on site on one line every day.
2) Ensure that checkers carry out checks on an item-by-item basis, not filling in multiple items at a time.
3) Checks shall be completed within a limited time (5 min or so) in a time-efficient manner.
4) Occasionally join operators carrying out checks to confirm equipment and standards are free of
problems.
5) Verify that selected check items, details, frequencies and check methods are appropriate.

Daily maintenance check supplementary information 2
Check Items before and after Long Shutdown
Poor action before or after a long shutdown can result in abnormalities that would not occur in ordinary
production. In addition to ordinary daily maintenance checks, prepare check sheets (including quality checks
and staffing situation) for use before and after a long shutdown to prevent abnormalities.
▼ Concrete examples
Select items deemed necessary within the company and prepare check sheets.
4M Key Point before Long Shutdown
Equipment shutdown
▼ Compressor shutdown
Unload materials in process or consume them all.
▼ Molding machine, casting machine, etc.
Machine
Calender timer setting
(Maximum setting is one week.)
▼ Heater power supply to preheat equipment
Protect equipment and jigs from rust, dirt and
dust.
▼ Apply specified rust inhibitor.
▼ Use a cover to ensure protection from dirt and
dust.
Completion of a set of operations and control of
Method
treated parts in furnace
▼ Completion of annealing
▼ Completion of dehydrogenation after plating
▼ Completion of tempering after hardening
Abnormality corrective actions and temporary
storage of parts and materials
Material
▼ Indication of current status and isolation
▼ Place parts and materials in regular storage
location.
▼ Tidy up red boxes and defective parts storage
location.
Personnel management
▼ Attendance schedule following long shutdown
▼ Travel destination survey
▼ Prepare a list of emergency contact details.
Man
Improvements/Construction work during long
Other
shutdown
▼ Prepare a construction work list.
(Equipment name, construction worker, impact,
process manager, etc.)
Control of theft, fire and hazardous and flammable
materials
▼ Check counts/quantities and lock doors.
▼ Ensure safety and security.
Measures to counter wind and flood damage to
buildings
▼ Prevent roof leaks and fasten doors.
Action Description
(5W1H)
(§ 2-4/5)
○: no problem
×: problematic
Result Key Point after Long Shutdown Result
Malfunctioning or capacity degradation due to
poor lubrication or decrease in air pressure
▼ Draining of pneumatic line
▼ Unusual noise/less than optimal equipment
motion
Equipment that takes time before achieving
settings might fail to meet manufacturing
conditions.
▼ Preliminary drying of resin materials
▼ Equipment that requires preheating, such as a
solder bath, plating bath and furnace
▼ Rechecking of settings
Rust inhibitor on finished goods/parts
▼ Remove rust inhibitor.
▼ Effects of static buildup in cover
▼ Check finished goods/parts for dirt and dust.
Unclear end of operations causing a skipped
process
Damage to internal structures
▼ Verify the completion of a set of operations.
▼ Keep or discard parts remaining in furnace
Parts/materials of unknown current status brought
into manufacturing line might result in defects.
FIFO might not be followed.
▼ Investigate the current status of
parts/materials, and isolate or discard them.
▼ Check materials for deformation and
degradation.
Personnel management
▼ Attendance situation
▼ Individuals’ health conditions and auspicious
or inauspicious occasions
Provide operators with work instructions once
again.
▼ Mistakes in operation or skipped processes
(After holidays, operators might omit or have the
wrong idea about some steps.)
Determine the impact on quality and output and
inform it to the required areas/departments.
Conduct quality checks.
▼ Research on improvement and construction
methods.
▼ Initial inspection
Check counts and quantities.
▼ Storage conditions
Damage by wetting
▼ Wetting of or rust formation on finished
goods/parts/equipment
Occurrence of other abnormalities
 (§ 2-5/5)
Daily maintenance check supplementary information 3

Form 2 Daily maintenance check sheet (example) BMP-441-04K 10/10

Date: Div./Dept.:
Asset no. Line no. Machine name Person Manager Assistant Standard no.
responsible for Manager
maintenance

Schematic drawing Symbol Check result notation

 Pass (no problems detected)
 Fail (If a problem is detected, note the reason and action in the remarks field.)
 Pass after action/adjustment (Describe the action in the remarks field.)
Numeric value Where criteria provide meter readings/counts.
Numeric value Pass after action/adjustment (Describe the action in the remarks field.)
| Nonoperating (If equipment is not used on a day, fill a vertical line in the check box.)

Frequenc 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 3 3
No. Timing Check point/item Criterion Check method 1 2 3 4 5 6 7 8 9
y 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1
Mechanical action and each motor not
11 Before operation 1/D Emergency stop switch Operation 
in operation
10.
1 Before operation 1/D Pressure gauge 10 Mpa - 10.5 Mpa Visual 0
Hydraulic drive motor/Thermo- No discoloration, unusual noise or
2 During operation 1/D Visual 
label offensive odor
Oil level gauge inside
3 During operation 1/D Level gauge reading within limits Visual/Auditory 
hydraulic tank
No discoloration, unusual noise or
4 During operation 1/D Motor/thermo-label Visual/Auditory 
offensive odor
Pressure control valve/Lock Lock nut with set mark shall not be
5 Before operation 1/W Visual/Auditory
nut with set mark loose.
Oil level gauge on speed
6 During operation 1/W Level gauge reading within limits Visual
change gear
No discoloration, unusual noise or
7 During operation 1/W Pilot motor/Thermo-label Visual/Auditory
offensive odor
Continuously variable No discoloration, unusual noise or
8 During operation 1/W Visual/Auditory
transmission/Thermo-label offensive odor
9 Before operation 1/M Pulley No wear or looseness Visual/Auditory
10 Before operation 1/M V-belt No cracks, wear or slip noise Visual/Auditory

Checker’s signature
* Monthly check date for this month: Friday, 26
Checks investigated by (Friday, weekly)
Action
Revision Revis Check
Revision date Key point of revision date & Action description Result
code ed by ed by

Remarks
time
 (§ 2-6/5)

Tokai Rika Co., Ltd.