7 Steps for Evolving Autonomous Maintenance

Step Name
1 Initial clean-up All-around clean-up of dust and dirt, centering on equipment proper, and
implementation of lubrication, and machine parts adjustment; discovery and
repair of malfunctions in equipment

2 Measures against Sources Prevent causes of dust and dirt and scattering, improve places which are difficult
to clean and lubricate and reduce the time required for clean-up and lubrication.

3 Formulation of clean-up and Formulate behavioral standards so that it is possible to steadily sustain clean-up,
lubrication standards lubrication and machine parts adjustment in a short period (Necessary to indicate
a time frame-work that can be used daily or periodically).

4 Overall inspection Training in check-up skills through check-up manuals; exposure and restoration
of minor equipment defects through overall check-ups

5 Autonomous check-up Formulation and implementation of autonomous check-up sheets

6 Orderliness and tidiness
Standardize various types of on-the job management items and devise complete
systematization of up-keep management.
Standards for clean-up, check-ups and lubrication
Standards for physical distribution in the workplace
Standardization of data records
Standardization of die management, jigs and tools

7 All-out autonomous Development of corporate policies and goals, and making improvement activities
management routine : Steadily record MTBF analysis, analyze these, and carry out equipment
improvements
 7 types of abnormalities
1. Minor Flaws
2. Unfulfilled Basic Conditions
3. Inaccessible places
4. Contamination sources
5. Quality Defect Sources
6. Unnecessary and non-urgent items
7. Unsafe places
 1. MINOR FLAWS
Contamination Dust, Dirt, powder, oil, grease, rust, paint
Damage Cracking, crushing, deformation, chipping, bending,
Play Shaking, falling out, tilting, eccentricity, wear, distortion,
corrosion,
Slackness Belts, Chains

Abnormal Unusual noise, overheating, Vibration, strange smells,

Phenomenon discoloration, incorrect pressure or current
Adhesion Blocking, hardening, accumulation of debris, peeling,
malfunction
 2. UNFULFILLED BASIC CONDITIONS
Lubrication Insufficient, Dirty, Unidentified, unsuitable, Leaking

Lubrication Supply Dirty, damaged or deformed lubricant inlets, faulty

lubricant pipes

Oil level gauges Dirty, Damaged, leaking, No indication of correct level

Tightening Nuts and Bolts slackness, Missing, Cross-threaded,

Too long, Crushed, Corroded, Unsuitable washers,
wing nuts on backward
 3. INACCESSABLE PLACES
Cleaning Machine construction, Covers, Layout, footholds, Space

Checking Construction, Covers, Layout, footholds, Instrument position

and Orientation, Operating Range display

Lubricating Position of lubricant inlet, construction, height, footholds,

lubricant outlets, space

Tightening Covers, Construction, Layout size, Space

Operation Machine layout, Position of valves, Switches and leavers,

Footholds

Adjustment Position of pressure gauges, thermometers, flow meters,

moisture gauges, vacuum gauges, etc.
 4. CONTAMINATION SOURCES
Product Leaks, Spills, Spurts, Scattering, Overflow
Raw materials Leaks, Spills, Spurts, Scattering, Overflow
Lubricants Leaking, Spills, Seeping oils, Hydraulic fluids, Fuel oils,
etc.

Gases Leaking compressed air, gases, steam, vapors, exhaust

fumes, etc.

Liquids Leaking water, Hot, Cold, half finished products, Waste

water, Leaking supply lines etc.

Scrap Flashes, cuttings, packaging materials, and non

conforming products.

Others Contaminants by people & Forklifts, Infiltration through

cracked walls, broken windows etc.
 5. QUALITY DEFECT SOURCES
Foreign Matter Dust, Rust, powder, chips, moisture, wire scraps, wood
pieces, paper pieces, stones etc.

Shock Dropping, Jolting, collision, Vibration etc.

Moisture Too little or Too much, infiltration
Gain Size Abnormalities in screens, Compressed air separators,
centrifugal separators,

Concentration Inadequate warming, heating, compounding, mixing,

evaporation, stirring etc.

Viscosity Inadequate warming, heating, compounding, mixing,

evaporation, stirring etc.
 6. UNNECCERY AND NON-URGENT ITEMS
Machinery Pumps, fans, compressors, columns, tanks etc.
Piping equipment Pipes, hoses, ducts, valves, dampers etc.
Measuring Temperatures, pressure gauges, vacuum gauges,
instruments ammeters etc.
Electrical equipment Wiring, piping, power leads, switches, plugs etc.

Jigs & Tools General tools, cutting tools, jigs, molds, dies, frames etc.

Spare parts Standby equipment, spares, permanent stocks, auxiliary

materials, etc.

Makeshift repairs Tape. String, wire, metal plates etc.

 7. UNSAFE PLACES
Floors Unevenness, cracked, holes, projections, peeling, wear of steel
chucker plates, slipping.
Steps Too steep, irregular, slipping, missing handrails, etc.
Lights Dim, out of position, dirty or broken covers, no explosion
proofing, etc.
Rotating Displaced, fallen oil or broken covers, not safe for emergency,
machinery missing emergency stop devices
Lifting Wires, hooks, brakes and other parts of cranes and hoists etc.
Devices
Others Special substances, solvents, toxic gases, insulating materials,
danger signs, protective clothing etc.
EXAMPLE OF ABNORMALITY
( LOOSE FITTINGS )
EXAMPLE OF ABNORMALITY
( LEAKAGES )
 HARMFUL EFFECTS OF INADEQUATE CLEANING

Failure Dirt and foreign matter penetrates rotating parts, sliding parts,
pneumatic and hydraulic systems, electrical control systems and
sensors etc., causing loss of precision, malfunction and failure as a
result of wear, blockage, frictional resistance, electrical faults etc.
Quality Defects Quality Defects are caused either directly by contamination of the
product with foreign matter or indirectly as a result of equipment
malfunction.

Accelerated Accumulated dust and grime make it difficult to find and rectify
Deterioration cracks, excessive play, insufficient lubricants, and other disorders,
resulting in accelerated deterioration.

Speed Losses Dust and dirt increase wear and frictional resistance causing speed
losses such as idling and under performance.
Points to be checked during
initial cleaning (Sample)
 Checkpoints for Nuts & Bolts
Slight defects Loose nuts & bolts, missing nuts & bolts

Bolt length All bolts should protrude from nuts by 2-3 threads
Washers Are flat washers used on long holes
Are tapered washers used on angle bars & channels
Are spring washers used for parts subjected to vibration
Are identical washers used in identical parts

Fixing of nuts Are bolts inserted from below, are they visible from outside
& bolts Are devices such as limit switches fastened at least by 2
bolts
Are wing nut direction clock wise
 Lubrication checkpoints
Lubricant Are lubricant sores always kept clean, tidy, are 5S principles applied
storage Are lubricant containers always capped
Are lubricant type clearly indicated and is proper stock control
practiced

Lubricant Are grease nipples, speed reducer lubricant ports and other lubricant
inlets inlets always kept clean
Are lubricant inlets dust proofed
Are lubricant inlets labeled with correct type and quantity of lub.

Oil level Are oil level gauges always kept clean, are oil levels easy to check
gauges Is the correct oil level clearly marked
Is equipment free of oil leaks, and oil pipes& breathers unobstructed

Auto Lub Are Auto lubricating devices operating correctly & supplying correct
Devices quantity of lubricants

Lubricating Are rotating, sliding parts, and transmission well lubricated

condition Are the surroundings free of contamination by excess lubricant
 Transmission System checkpoints
V-Belts & Are any belt cracked, swollen, worn out, or contaminate by lub.
Pulleys Are any belts twisted or missing. Are any belts stretched or slack
Are multiple belts under uniform tension and all of the same type
Are top surfaces of belts protruding above the pulley rims? Are the
bottoms any pulley groves shiny (indicating a worn belt or pulley)
Are pulleys correctly aligned

Roller Are any chains stretched 9indicating worn out pins or bushings
chains Are any sprocket teeth worn, missing or damaged
Is lubrication between pins and bushings sufficient
Are sprockets correctly aligned

Shafts, Is there any overheating, vibration, abnormal noise due to excessive

Bearings & play, or lack of greasing. Are any keys or set bolts loose or missing
Couplings Are any couplings misaligned or wobbling, Are any seals worn out

Gears Are gears rightly lubricated with proper amount of lubricant.

Are any teeth missing, damaged worn out or jammed
Is there any unusual noise or vibration
 Hydraulic checkpoints
Hydraulic Is there correct quantity & level indicated for fluid in the reservoir
Checkpoints Is fluid of correct Temp. And is min & max for temp. indicated
Is fluid cloudy (indicating air entrapment
Are all fluid inlets & strainers clean, are any suction filters blocked
Are any fluid reservoir breather filters blocked
Are fluid pumps operating without any unusual noise or vibration
Are hydraulic pressure correct, and are operating ranges displayed

Heat Is any fluid or water leaking from fluid coolers or pipes

Exchangers Are temp. differences between fluid & water inlets & outlets are
correct ? Are any tubes blocked
Hydraulic Are there any fluid leaks ? Are hydraulic properly fastened?
Equipment Are hydraulic devices operating correctly without speed loss or
breathing? Are hydraulic pressure correct? And all gauges working
Piping and Are all pipes and hoses fastened tightly?
Wiring Are there any fluid leaks? Are any hoses cracked or damaged?
Are all valves operating correctly? Is it easy to see whether valves are
open or closed/ Are any pipes, valves unnecessary?
 Pneumatic checkpoints
FRLs Are FRLs clean? Is it easy to see inside of them? Are they fitted right
way around?
Is there sufficient oil. And are the drains are clear?
Is the oil dip rate correct ?(approx 1 drop for every 10 strokes)
Are the FRLs installed not more than 3 m from the equipment?
Are the pressure adjusted to the correct value and operating ranges
are clearly indicated?

Pneumatic Is compressed air leaking from pneumatic cylinders or solenoids?

Equipment Are all pneumatic cylinders and solenoid valves firmly fastened?
Are any pistons dirty, worn, damaged?
Are the speed controllers installed right way around?
Is there any abnormal sound or overheating of solenoid valves, and
are any lead wires chafed or trailing?

Piping and Are there any places in pneumatic pipes or hoses where fluid is liable
Wiring to collect? Are all hoses and pipes clipped firmly in place?
Are any hoses cracked, damaged, are there any air leaks?
Are valves operating correctly and open and close position known
 Electrical Checkpoints
Control Are the interiors of distribution boards, switch boards, and control
Panels panels kept clean, tidy, and well organized by the application of 5S
activities? Have any objects or flammable materials been left inside
Is the wiring inside control panels in good condition? Are any wires
coiled or trailing?
Are all ammeters and voltmeters operating correctly?
Are any switches, bulbs broken? Do all switches work correctly?
Are panel doors in good condition? Do they Open & close easily?
Are there any unused holes? Are control panels water& dustproof?

Electrical Are all motors free of overheating, vibration, unusual noise & smell
Equipment Are al motor cooling fans and fins are clean?
Are any bolts loose? Are pedestals free of cracks and damages?
Sensors Are all manual switches clean and free of damages & excessive play
Are all switches installed in the correct position
Are the interiors of limit switches is clean? Are any wires coiled or
trailing?
Are any limit switch dogs worn, deformed, or of the wrong shape?
 Electrical Checkpoints Cont.
Sensors Are all photoelectric switches and proximity switches clean and free of
excessive play?
Are any sensors out of position? Are correct positions clearly indicated?
Are all lead wires un-chafed, and is insulation intact at entry points?

Switches Are all switches installed in the correct position

Are all manual switches clean and free of damages & excessive play
Are emergency stop switches installed in appropriate locations and are
they in good working condition?

Piping and Are any pipes, wires, or power leads loose or unsecured?
Wiring Are any ground wires damaged or disconnected?
Are any pipes damaged or corroded? Are there any bare wires or wires
with damaged insulation?
Are any wires coiled on the floor or dangling overhead?
White tags for operators Red Tags to be attended by Maint.

Equipment Name Equipment Name

Control No.. Control No..

Date of detection. Date of detection.

Detected by.. Detected by..

Description of Minor defects Description of Minor defects

. .

.. ..

. .
 o
n
S

location
Exact description of
Abnormality

Dirt
leak
splash/spillage
loose
missing
wear
broken
chipping
bent
holes/gap

abnormal noise
excess heat
Abnormality - tag matrix

vibration
discoloration
abnormal movement

Breakdowns
Quality rejects
Cost increase
leads to

Power increase
Abnormality
 List of Abnormalities in the Equipment
Equipment Name : ______________________ Unit Name : ___________________________ No. :
______________
Why is it Abnormality
Date of Why did it become Contents of the
Abnormality Abnormality? (What tag Planned Date of
No. Detec- Detector so? (What is the Countermeasure Executor
Item will happen if it is left Classifica- Date completion
tion cause?) s
as it is?) tion
 List of illustration of hard-to-access areas
Equipment Name : ______________________ Unit Name : ___________________________ No. :
______________
Abnormality
Date of Items Cleaning
Detecto Contents of the tag Planned Date of
No. Detec- Lubrication Difficult Portions Difficult State Executor
r Countermeasures Classifica- Date completion
tion Inspection
tion

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