STEP 3

TOTAL
PRODUCTIVE
MAINTENANCE
STEP 3 AUDIT
Autonomous Maintenance and Focused Improvement

This audit serves as requirement to ensure alignment to JIPM standards and

also for progression in the TPM cluster.

AUTONOMOUS MAINTENANCE STEP 3

The purpose of this audit is to ensure the Step 2 requirements of Autonomous

Maintenance are being fulfilled. The requirements have been cross referenced with the
Japan Institute of Plant Maintenance excellence award criteria.
Rating Scale: major deviation or more = 0,
exceeding expectations = 3, superior=4

minor deviation= 1, meet expectations =2,

STEP 3 AM CLEANING, INSPECTION AND LUBRICATION

STANDARDS
REQUIREMENT
cleaning
and

SCORE

Details
of
inspection
standards:
- Visuals in place, eg: flow direction marks,
bolt match mark, pressure gauge range
marking, colour coded pipes.

______

______

Has the range of the cleaning and

inspection responsibilities been decided?

Are
the
methods
and
for cleaning and inspection decided?

Is the period and time for cleaning and

inspection set appropriately?

______

Cleaning standards are specific to this

machine and is the object of cleaning and
inspection clarified?

______

Is the cleaning status recorded on check

sheets
and
is
this
conscientiously
observed?

tools

Is inspection using senses evident based

on set standards (kpa, Nm, mm)

- Training and clarity among members

Details of oiling standard:
- Has the range of the Division of oil
responsibilities been decided?
-

Are the oiling methods and tools

decided and in a fixed location and near
the machine (5S of the storage location)?

RESPONSIBLE
Autonomous
Maintenance Pillar
Head

______

______

______

______

______

Autonomous
Maintenance Pillar
Head

______

TPM STEP 3 AUDIT

Are the period and time set appropriately?

Are the type, quality and quantity of oil

decided?

______
______

Is the objective of oiling clarified?

Is the oil easy to see and is the oiler

functioning normally?

______

Is the oiling inlet dirty? Also, are means

being devised to prevent it from being
dirtied?

______

Is a check sheet used to keep records and

is this done conscientiously?

______

Is the lubrication standards set? (How

much, who, why, How)

______

Current type of lubrication analysed?

Status
of
autonomous
maintenance
activities:
- Are the overall schedule and the current
month schedule clearly defined?

______

______

______

Is a record documenting losses being kept

so that problems can be reduced?

______

Are the results of countermeasures made

apparent through Kaizens or OPLs?

______

Are standards created in meetings and is

the importance of observing these
standards thoroughly communicated?

______

Autonomous
Maintenance Pillar
Head

Evidence requirements must be sought for each point to ensure the documentation is in
use and activities.

STEP 1 & 2 AM FOLLOW UP ON SOURCES OF CONTAMINATION

AND HARD TO AREAS
REQUIREMENT
Initial cleaning:
- Are clean conditions being maintained?
-

Is "Cleaning is Inspection" being observed

and are problems being identified?

SCORE
______

RESPONSIBLE
Autonomous
Maintenance Pillar
Head

______
TPM STEP 3 AUDIT

Are team members identifying problems

with greater detail and is the next step
after improving the skill of members
understood?
Sources and type of contamination:
- Are improvements being made to oiling
and are these improvements leading to
increased maintainability?
-

Are plans being drafted again for those

items which did not achieve adequate
results from the countermeasures?

Are further measures needed? (Are any

omissions in the countermeasures?)
Knowledge Test 1 Pillar Heads or Shop
Floor:
Where the most frequent losses and what
are they?
Operator to use the visual board and refer
to the loss map and OEE metrics and
explain them
Knowledge Test 1 Pillar Heads:
Explain four of the 7QC tools in detail. What
they are and where they are used and
provide examples that are well explained of
where the operators have used the tools to
solve problems.
Explain why the initial cleaning exercise is
performed daily? As a mechanism to inspect
and ensure equipment functioning.
Visual Advice:
Area standards provided with photos of what the
area should look like complete with labelling,
markings etc.
Preparation of tools:
- Cleaning tools are in place and are
adequate to clean in accordance with the
cleaning instruction. Operator to
explain the use of the tools using the
OPL if necessary
Contamination Sources:
- Operator to discuss the types of
contamination in detail, where they
occur, what they are and apply the
5why technique when requested.

______

______

Autonomous
Maintenance Pillar
Head

______

Autonomous
Maintenance Pillar
Head/Shop Floor

Autonomous
Maintenance Pillar
Head

Autonomous
Maintenance Pillar
Head
Autonomous
Maintenance Pillar
Head
Autonomous
Maintenance Pillar
Head

Autonomous
Maintenance Pillar
Head

TPM STEP 3 AUDIT

FOCUSSED IMPROVEMENT STEP 1-7

FOCUSSED IMPROVEMENT AUDIT
REQUIREMENT
Kaizen A3 Summary Sheet:
- Kaizens for cleaning, inspection and
lubrication improvements are provided
-

SCORE

______

Kaizens for loss reduction are clearly

labelled with impact in line with the KPIs
established and required.

______

Kaizens for cleaning improvement

focussing on the elimination of
contamination sources are provided and
the impact detailed accordingly.

______

RESPONSIBLE
Focussed
Improvement Pillar
Head

______

Kaizens for standard identification?

Kaizens have been closed off showing

some results to date of improvement
Stepped FI plan with a list of all projects:
A detailed list of projects, expected completion
date, responsible parties
Visual Board Update: All projects presented
onto the visual board and tracked as per the
weekly meetings. Team structures.
Training and Development Matrix: Who has
been trained, what is their level of competence
towards TPM? The matrix should follow a
competency check.

______
Focussed
Improvement Pillar
Head
Focussed
Improvement Pillar
Head
Education and
Training Pillar Head

STEERING COMMITTEE REQUIREMENTS

REQUIREMENT
SCORE
RESPONSIBLE
Declaration: A company communication
Focussed
stipulating the objectives and commitment to
Improvement Pillar
TPM.
Head
FI and AM Team Structures: Officiated
Focussed
organograms outlining team structures for the AM
Improvement Pillar
and FI pillars.
Head
KPIs: All projects and training are required to
Focussed
have KPIs linked to a master KPI allocation. These
Improvement Pillar
are then cross referenced with Kaizen events and
Head
Am activities.
TOTAL SCORE

TPM STEP 3 AUDIT

PERCENTAGE

RESULT

COMMENTS

AUDITORS:

PILLAR HEADS

STEERING COMMITTEE TEAM:

TPM STEP 3 AUDIT