Description

Autonomous Maintenance (Jishu Hozen) is one of the most important building blocks in any Total Productive Maintenance (TPM) program. Autonomous Maintenance refers to TPM activities that involve operators in maintaining their own equipment, independent of the maintenance department. 

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One of the basic principles of TPM is that operators are the first line of defense against unplanned equipment downtime. Operators and others in daily contact with equipment can use their knowledge and familiarity with operating conditions to predict and prevent breakdowns and other equipment-related losses. They do this through regular cleaning and inspection of equipment, and through team-based autonomous. maintenance activities that tackle equipment-related problems.

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Activities in an Autonomous Maintenance program include: daily inspections, lubrication, parts replacement, simple repairs, abnormality detection and precision checks.

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The goals of the Autonomous Maintenance program are to prevent equipment deterioration, restore equipment to its ideal state, and establish basic conditions needed to keep equipment well maintained.

 

Developed by our JIPM-certified TPM instructor, this Autonomous Maintenance (Jishu Hozen) PPT presentation is packed with diagrams, examples and practical tips and can be used to train shopfloor staff participating in autonomous maintenance activities. 

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Note: This training package includes:

1. Autonomous Maintenance (Jishu Hozen) PPT training presentation (PowerPoint format)

2. The Seven Steps of Autonomous Maintenance (Jishu Hozen) poster (PDF format, in color and monochrome, printable in A3 size)

3. Autonomous Maintenance (Jishu Hozen) Framework poster (PDF format, in color and monochrome, printable in A3 size)

 

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Learning Objectives​



1. Understand the key concepts of TPM and AM activities

2. Learn how to implement the AM activities, step by step

3. Learn how to use activity boards, meetings and one-point lessons to promote TPM goals

4. Learn how to measure and audit AM activities and performance

5. Familiarize with the JIPM TPM excellence criteria for AM

6. Understand the critical success factors in sustaining AM activities on the shopfloor

 

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Contents​

 

1.  Overview of TPM

• Common Features of Workplaces with Poor TPM Implementation

• Machine Failures Have Many Hidden Causes

• What is TPM?

• TPM Principles

• TPM Provides a Basic Foundation for Lean Transformation

• TPM Eliminates/Reduces Waste

• TPM Drives the “Three Evils” Out of the Workplace

• Why Is TPM Important?

• TPM Goals

• Eight Pillars of TPM

• TPM Benefits

 

2.  Introduction to AM

• What is AM?

• What AM is Not

• AM is a Paradigm Shift

• AM Supports a Culture Change

• AM Activities Improve Equipment Efficiency & Upgrade Operator Skills

• ​Accidents Occur When Unsafe Conditions Combine With Unsafe Behavior

• Characteristics of AM Programs

• Goals of AM

• Natural & Forced Deterioration

• Four Equipment- related Skills for Operators

• AM Approach

• Activities Betond the Scope of AM

 

3.  Tools of AM

• 3 Key Tools for AM

• Activity Board

• Use of Activity Boards

• Examples of Activity Board

• Guidelines for Team Meetings

• What is One-Point Lesson?

• 3 Purposes of One-Point Lesson

• Philosophy of One-Point Lesson

• One-Point Lessons as a Cascading Tool

• Types of One-Point Lessons

• Examples of One-Point Lessons

 

4.  How to Implement the Seven Steps of AM: The Step by Step Approach

• 7 Steps of AM

• Step 1 - Clean & Inspect

• Step 2 - Eliminate problem sources and inaccessible areas

• Step 3 - Draw up cleaning and lubricating standards

• Step 4 - Conduct general inspections

• Step 5 - Conduct autonomous inspections

• Step 6 - Standardize through visual workplace management

• Step 7 - Implement autonomous equipment management

 

5.  Measuring & Auditing AM Activities

• TPM Metrics - What to Measure?

• Possible Metrics for AM

• Three Important Reasons for Audits

• Key Implementation Points of AM

• Managers Must Play an Active Role

 

6.  JIPM TPM Excellence Criteria for AM

• JIPM Excellence Criteria for AM

 

7.  Sustaining AM

• How to Sustain AM?



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You may also be interested in the following training presentations and documents (sold separately):

1. Total Productive Maintenance (TPM)

2. Autonomous Maintenance (Jishu Hozen)

3. Focused Improvement (Kobetsu Kaizen)

4. Planned Maintenance

5. Quality Maintenance (Hinshitsu Hozen)

6. Overall Equipment Effectiveness (OEE)

7. TPM Team Guide

8. TPM Self-Assessment Guide & Tool

9. TPM Autonomous Maintenance Audit Guide & Checklists

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