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Step 1 Diagnosis Sheet

Subsection Section TPM Autonomous Maintenance Step 1 Diagnosis date: __/__/__ General inspection Try again
Department Diagnosis Sheet for Initial Cleaning Diagnosed by __/100 points Pass
Target equipment: 80 points or more

VIEWPOINT Diagnosis points and items cited


Evaluation points
Look, touch, listen, smell
Is cleaning being Breakage, wear, Are there any Not oiled Are difficult-to- Problems uncovered Problems exhaustively Problems not yet Problems continue to No attempting to find
done so that the deformation, defects in the Inadequate oiling access cleaning and countermeasures uncovered but completely uncovered arise problems
things can be defects, play and positioning or Amount of oiling and oiling completed countermeasures not
inspected? dirtying of parts attachment of unknown locations made yet completed
Chemicals, waste, parts or Not visible tangible?
dust, rust (?), loosening of nuts No level indicator
mist, paper, and bolts?
scraps, scales,
glass shards,
metal scraps

AREA
The machine 7 5 3 2 0
surroundings are:
Floor, wall, pillar, inside
a pit, curtain, ceiling 6 4

Have you
exhaustively The machine exterior 9 7 4 2 0
uncovered is: Frame, piping,
problem wiring, etc.
points from a 8 6 3
functional
point of
The machine interior 15 11 5 2 0
view? Have
is: Mechanical, optical,
you
sensors
corrected
13 7 3
those that
can be dealt
with? Peripheral equipment 8 6 4 2 0
includes

7 5

Spare parts 6 4 2 1 0
consumables, jiig and
tools, measuring
instruments

Control Panel, electrical 7 4 2 1 0


system, motor, pump

6 3

Comments

____ / 52 points

Item Guidance Item Evaluation level and evaluation points


Are the sources that generate dirt, leakage (oil, chemicals Understands Undertsands for the Only half understands Does not understand Has almost no
and air), waste, and dust understood? completely and keeps most part many parts undertsanding
records
5 4 3 2 0
Are
Are the amounts of leakage (supplemental amounts) and Understands Undertsands for the Only half understands Does not understand Has almost no
countermeasu
falling dust understood? completely and keeps most part many parts undertsanding
res being
records
taken for the
generating 4 3 2 1 0
sources of Are efforts being made to take Taking measures Fundamental measures Temporary measures Partial measures are Create plan for Almost no work done at
waste, dirt, countermeasures for generating sources? on one's own are completed are completed completed countermeasures all
rust and
leakage
5 4 3 2 0
Requesting Plan for Drafting of plan Separated items to be Almost no work done at
others countermeasures is together with others in requested to others all
clear progress
3 2 1 0
Are measures being taken to prevent Taking measures Completed Completed partial Gathering ideas Isn't coming up with In a disposition to give
Are
splashing of chemicals, mist, oil and on one's own countermeasures with countermeasures good ideas up
countermeasu
water? good ideas
res being
Are measures being devised for 4 3 2 1 0
taken to
materials, attire, writing implements and Requesting Plan for Drafting of plan Separated items to be Almost no work done at
prevent
paper? others countermeasures is together with others in requested to others all
splashing and
to prevent clear progress
the 3 2 1 0
introduction Comments
of waste?
____ / 24 points

Evaluation Standard Data collection in Discussions have


Visually understood Created a report Not started at all
Item progress started

(1) Are the number of problem points understood and their relationship to the 7 major losses understood?

5 4 3 2 0
(2) Is the effectiveness of autonomous maintenance grasped in a visual form (failure losses, minor stoppages losses,
What is the speed losses, and set up and adjustment losses)?
5 4 3 2 0
status of
visual (3) Are review meetings held and do all members understand the problem points of that day?
autonomous 5 4 3 2 0
maintenance
(4) Are suggestions for improvement being made?
activities?
4 3 2 1 0
(5) Are future methods to advance the process systematic? (Motivating slogans and future autonomous maintenance
plan)
5 4 3 2 0
Comments

____ / 24 points

AM 1step diagnosis sheet JIPM


Step 2 Diagnosis Sheet

Subsection Section TPM Autonomous Maintenance Step 2 Diagnosis date: __/__/__ General inspection Try again
Department Diagnosis Sheet for sources of dirt and Diagnosed by __/100 points Pass
Target equipment: difficult-to-access locations countermeasures 80 points or more

Diagnosis point Cited Items Evaluation points


Is the level from Step1 being maintained? Even cleaner than when Established in daily The level when passed Passably clean Slipped back to former
passed activities is being maintained condition
8 7 6 4 0
Are the
conditions Are they changing their viewpoint and uncovering problems ? Changing their Uncovering problems a Uncovering almost no
for passing viewpoint and little at time problems at all
Step 1 being uncovering many
maintained? problems rapidly
8 7 6 4 0

Comments ___ / 16 points


Are the respective generating sources being revealed? Completely revealed For the most part About half Less than half Not revealed at all

4 3 2 1 0
Are the respective amounts generated understood? Completely understood For the most part About half Less than half Not revealed at all

4 3 2 1 0
Are the respective generating sources understood? Completely understood For the most part About half Less than half Not revealed at all

Countermeasures for 4 3 2 1 0
generating sources of Are measures that can be taken within the section being taken, and are Results are clearly Tentative results are Countermeasures are Countermeasures are in Countermeasures are
leaks, rust, dirt and results being obtained? being obtained being obtained completed, but results progress not being taken
waste are not yet obtained
4 3 2 1 0
What about problems for which countermeasures were requested to Request completed and Execution in progress Request in progress Drafting of plan for Not yet started
other departments, and are results being obtained? results are being countermeasures in
obtained progress
4 3 2 1 0

Progress of
counter
Comments ___ / 20
measures for
Have the generating sources for scattering (chemicals, mist, oil, water, Completely made For the most part About half Less than half Not revealed at all
generating
etc.) been made tangible? tangible
sources
4 3 2 1 0
Is the amount of scattering and the amount of waste introduced Completely understood For the most part About half Less than half Not revealed at all
understood?
4 3 2 1 0
Are the sources of scattering and introducing waste understood? Completely understood For the most part About half Less than half Not revealed at all

Prevention of 4 3 2 1 0
scattering and Are the countermeasures that can be taken within the section being Results are clearly Tentative results are Countermeasures are Countermeasures are in Countermeasures are
countermeasures for taken, and are results being obtained? being obtained being obtained completed, but results progress not being taken
introducing waste are not yet obtained
4 3 2 1 0
What is the status of problems for which requests were made to other Request completed and Request completed Request in progress Drafting of plan for Not yet started
departments and are results being obtained? but results not yet countermeasures in
obtained progress
4 3 2 1 0

Comments ___ / 20
Have the difficult to access cleaning and oiling locations been revealed? Have been completely For the most part About half Less than half Not revealed at all
revealed
4 3 2 1 0
Are the countermeasures being taken to make the machine vicinity easy to clean? Countermeasures For the most part About half Less than half Not revealed at all
completed
4 3 2 1 0
Are measures being taken to make the machine interior easy to clean? Countermeasures For the most part About half Less than half Not revealed at all
completed
4 3 2 1 0
Do piping and wiring get in the way of cleaning? Countermeasures For the most part About half Less than half Not revealed at all
What is the
completed
status of
4 3 2 1 0
countermeasu
res for Are efforts being made to increase the interval of cleaning and oiling? Effectiveness is Some effectiveness In progress Under consideration Not yet started
difficult to recognised
4 3 2 1 0
access
cleaning and Are efforts being made to reduce the time for cleaning and oiling? Greatly reduced Reduced Reduced somewhat In planning Not yet started
oiling
locations? 4 3 2 1 0
What about the problems for which countermeasures were requested to other departments? Countermeasures Request completed Request in progress Drafting of plan for Not yet started
completed countermeasures in
progress
4 3 2 1 0
Have preparations been made for Step 3 (creation of cleaning and oiling standards)? Preparation completed For the most part Preparation in progress Not yet started

3 2 1 0
Comments

___ / 35
Have the themes been subdivided, and are the subdivided themes being pursued with specific Adeguately subdivided Satisfactory Some parts adeguately Not subdivided
numerical values? and clarified pursued

3 2 1 0
Are the results of PDCA in a form that can be understood? Indicated in a manner Normal Difficult to understand Not subdivided
that is easy to
Status of
understand
autonomous
3 2 1 0
maintenance
activities Are the schedule and results of meetings indicated? Indicated in a manner Normal Difficult to understand Not subdivided
that is easy to
understand
3 2 1 0
Comments

___ / 9

AM 2step diagnosis sheet JIPM


Step 3 Diagnosis Sheet

Subsection Section TPM Autonomous Maintenance Step 3 Diagnosis date: __/__/__ General inspection Try again
Department Diagnosed by __/100 points Pass
Diagnosis Sheet for Creating Cleaning and Oiling Standards
Target equipment: 80 points or more

Diagnosis Point Evaluation Points


Are clean conditions being maintained? Cleaner than when Maintained as when Passably Below the level when Dirty
Step 1 passed passed passed
Maintenance and 5 4 3 2 1
improvement of Are Cleaning and Inspection being observed, are problems being identified? Being identified Cleaning is inspection Could do better Marking time Regressing
conditions when initial
cleaning step was passed 5 4 3 2 1
Are workers identifying problems with greater details, and is the next step after improving the skills of Skills improved Skills improved Greater detail No change in details Lesser detail
Purpose
members understood? remarkably
Provision of base
5 4 3 2 1
conditions

Comments ___ / 15 points

Diagnosis Point Evaluation Points


Step2 Are the improvements being made to oiling and are these improvements leading to increased maintenability? Maintenability is Could do better Oiling improved Not yet No improvement
Status of follow up on improved
generating sources, 5 4 3 2 1
difficul to access Are plans being drafted again for those items which did not achieved adequate results from the Meticolously planned Plan drafted Drafting of plan in Drafting of plan Not yet started
cleaning and oiling countermeasures? progress scheduled
locations, and 5 4 3 2 1
Countermeasures
Are further measures needed? (are any omissions in the countermeasures?) No blind spots Almost completely Could do better Not yet Greatly needed
unneeded
Purpose
4 3 2 1 0
Improve realibility and
mantainability
Comments ___ / 14 points

Diagnosis Point Evaluation Points


Where? Has the range of the division of oil responsibilities been decided? Firmly decided Decided Passably Not decided
Who? 4 3 2 1
Are the methods and tools for cleaning and inspection decided? Firmly decided Decided Passably Not decided
By what method?
4 3 2 1
Details of cleaning and When? Are the period and time for cleaning and inspection set appropriately? Set appropriately Could do better Not yet Not decided
inspections standards How much? 4 3 2 1
Is the object of cleaning and Inspection clarified? Clarified Could do better Not yet Not decided
Purpose What?
4 3 2 1
Maintenance and control
Is the cleaning status recorded on check-sheets, and is this consciously observed? Observance of this
of cleaning and Procedure is observed,
procedure can be seen Could do better Not recorded
inspection but not clearly
visually

4 3 2 1

Comments ____ / 20 points

Diagnosis Point Evaluation Point


Where? Has the range of the division of oil responsibilities been decided? Firmly decided Passably Not decided
Who? 3 2 1
Are the oiling methods and tools decided, and in a fixed location (5S of the storage In a fixed position Passably Not decided
By what method?
location)? 3 2 1
When? Are the period and time set appropriately? Firmly decided Passably Not decided
How much? 3 2 1
Are the type and quantity of oil decided? Decided Passably Not yet decided
3 2 1
What?
Is the object of oiling clarified? Clarified Passably Unclear
Details of oiling 3 2 1
standard Clean, is the oil easy to see, and is the oiler functioning normally?
Not functioning
Relevant Is the automatic oiling equipment functioning normally? Functioning normally Passably
Purpose normally
equipment Are the grease cap and oil cap functioning normally?
Maintenance and control 3 2 1
of oiling
Have all systems been checked to verify that the oiling equipments is functioning to the maximum level? Verified For the most part Not yet started
3 2 1
Is the oiling inlet dirty? Also, are means being devised to prevent it from being dirtied? Good Passably Dirty
3 2 1
Is a check-sheet used to keep records, and is this done conscientiously? Observance of this Passably Not clear whether
procedure can be seen procedure is being
visually observed
3 2 1

Comments ____ / 27 points

Diagnosis Points Evaluation points


Are the overall schedule and the current month schedule clearly defined? Clearly defined Passably Could do better Unclear
4 3 2 1
Is the record documenting losses being kept so that the problems can be reduced? Conscientiously
Passably Could do better Not recorded
recorded defined
4 3 2 1
Status of Autonomous Are the results of countermeasures made apparent? Made easy to
Passably Could do better Not displayed
Maintenance activities understand
4 3 2 1
Purpose Activity Board Are standards created in meetings, and is the importance of observing these standards Thoroughly Passably Could do better Not Thoroughly
Development of and Meeting thoroughly communicated? 4 3 2 1
Autonomous
Is care taken so that all personnel know the number of improvement suggestions and their
Maintenance Easy to understand Passably Could do better Difficult to understand
implementation?
4 3 2 1
Are instructions and activities between members and managers firmly executed? Firmly executed Passably Could do better Not yet
4 3 2 1

Comments ____ / 24 points

AM 3step diagnosis sheet JIPM


Step 4 Diagnosis Sheet

Application Form for Autonomous


Section/ team name Application date Section Manager Leader
Maintenance Diagnosis
Autonomous Maintenance Diagnosis Assembly line to be
Sheet diagnosed

Desired diagnosis __/__/__


___Points Pass Fail
date
Step 4-1: General Inspection
(Lubrication) Diagnosis date __/__/__
Pass level
and time __:__ - __:__ ( of level points in items 1 - 6)
Diagnosis Autonomous Section Manager Top Executive Diagnosed by
Autonomous Section Manager Top Executive

90 points or 85 points or 80 points or


more more more

Bad Poor Fair Somewhat good Good


Diagnosis item Points of diagnosis Suggestions

20 points 40 points 60 points 80 points 100 points


Maintenance and control (Are operation and maintenance being performed for 1-3?)
- Are countermeasures for generating sources being adequately
maintained?
- Are the improvement conditions satisfactory for
countermeasures for difficult-to-access cleaning locations?
- Have cleaning and oiling standards been completed, and are
they being utilized accor+C12dingly?

1 point 2 points 3 points 4 points 5 points


1. Skill education - Are Leaders and Circle Members actively creating one-point
textbooks and raising their level of skill?

- Have all members mastered general inspection skills?

2. General inspection - Are the items of education steadily being inspected?

- Are problem locations being identified through inspection?

- Are countermeasures being taken for locations where


problems were identified?

3. Safety - Are minor defects related to safety being identified, and are
countermeasures being taken?

4. Site Diagnosis - Are labels properly stuck to oiling locations, and are means
(lubrication) being devised to enable oiling without omission ?

- Is the correct oil type being used?

- Is the amount of oiling appropriate?

- Is there any oil deterioration?

- Are oil pipes clogged or damaged?

- Is the oil to be supplied always available?

- Are oilers and oil lubricators managed by oil type ?

- Check for oiler and nipple damage and check for any adhering
waste or dust

- Is the oiler station managed by oil type? Is it always covered?


Is there any adhering waste or dust? Is it in the proper
position?
5. Tentative autonomous standards - Have tentative inspection standards been prepared?
inspection

- Have improvements been made to reduce the number of


inspection items?

- Have improvements been made to make inspection easier ?

- Are the inspection methods and period appropriate?

- Are means being devised so that inspection is performed


steadily and without omissions?

AM 4-1step diagnosis sheet JIPM


Step 4 Diagnosis Sheet

Application Form for Autonomous


Section/ team name Application date Section Manager Leader
Maintenance Diagnosis
Autonomous Maintenance Diagnosis Assembly line to be
Sheet diagnosed

Desired diagnosis __/__/__


___Points Pass Fail
date
Step 4-2: General Inspection
(Hidraulic and pneumatic) Diagnosis date __/__/__
Pass level
and time __:__ - __:__ ( of level points in items 1 - 6)
Diagnosis Autonomous Section Manager Top Executive Diagnosed by
Autonomous Section Manager Top Executive

90 points or 85 points or 80 points or


more more more

Bad Poor Fair Somewhat good Good


Diagnosis item Points of diagnosis Suggestions

20 points 40 points 60 points 80 points 100 points


Maintenance and control (Are operation and maintenance being performed for 1-3?)
- Are countermeasures for generating sources being adequately
maintained?
- Are the improvement conditions satisfactory for
countermeasures for difficult-to-access cleaning locations?
- have cleaning and oiling standards been completed, and are
they being utilized accordingly?

1 point 2 points 3 points 4 points 5 points


1. Skill education - Are Leaders and Circle Members actively creating one-point
textbooks and raising their level of skill?

- Have all members mastered general inspection skills?

2. General inspection - Are the items of education steadily being inspected?

- Are problem locations being identified through inspection?

- Are countermeasures being taken for locations where


problems were identified?

3. Safety - Are minor defects related to safety being identified, and are
countermeasures being taken?

4. Site Diagnosis - Check for leaks and bleeding from pipes and equipment
(Hydraulic and pneumatic )
- including water -
- Is the equipment dustproof?

- Check for abnormal noise or vibration in the pump motor.


Check for sounds at the beat frequency and abnormal odors in
the switching valve, solenoid, etc.

- Check the oil quantity and temperature of the oil pressure


unit?

- Are the air 3-points sets being used correctly (oil quantity,
filter dirt, etc.)?

- Check the hose mounting condition, and check for any


vibration, dirt and breakage.

- Are the pipes lying on the ground where they should not be?
Are they properly maintained?

- Are the pipes easy to inspect and maintain?

- Is the pressure gauge normal (indicator is appropriate and


easy to see)?

5. Tentative autonomous standards - Have tentative inspection standards been prepared?


inspection

- Have improvements been made to reduce the number of


inspection items?

- Have improvements been made to make inspection easier ?

- Are the inspection methods and period appropriate?

- Are means being devised so that inspection is performed


steadily and without omissions?

AM 4-2step diagnosis sheet JIPM


Step 4 Diagnosis Sheet

Application Form for Autonomous


Section/team name Application date Section Manager Leader
Maintenance Diagnosis
Autonomous Maintenance Diagnosis Assembly line to be
Sheet diagnosed

Desired diagnosis __/__/__


___Points Pass Fail
date
Step 4-3: General Inspection
(Drive) Diagnosis date __/__/__
Pass level
and time __:__ - __:__ ( of level points in items 1 - 6)
Diagnosis Autonomous Section Manager Top Executive Diagnosed by
Autonomous Section Manager Top Executive

90 points or 85 points or 80 points or


more more more

Bad Poor Fair Somewhat good Good


Diagnosis item Points of diagnosis Suggestions

20 points 40 points 60 points 80 points 100 points


Maintenance and control (Are operation and maintenance being performed for 1-3?)
- Are countermeasures for generating sources being adequately
maintained?
- Are the improvement conditions satisfactory for
countermeasures for difficult-to-access cleaning locations?
- Have cleaning and oiling standards been completed, and are
they being utilized accordingly?

1 point 2 points 3 points 4 points 5 points


1. Skill education - Are Leaders and Circle Members actively creating one-point
textbooks and raising their level of skill?

- Have all members mastered general inspection skills?

2. General inspection - Are the items of education steadily being inspected?

- Are problem locations being identified through inspection?

- Are countermeasures being taken for locations where


problems were identified?

3. Safety - Are minor defects related to safety being identified, and are
countermeasures being taken?

4. Site Diagnosis - Check for wear and deterioration of the V-belt. Check for
(Drive) wear and misalignment of the pulley.

- Is the tension of the V-belt cover?

- Are the direction of rotation and the dimensions of the belt


in use managed visually in the V-belt cover?

- Is an adequate amount of lubricating oil reaching the area


between the pin and bushings of the chain?

- Check for elongation and misalignment of the chain. Check for


interlocking of the sprocket due to wear.

- Check for overheating, vibration and noise in the bearing due


to bending of the shaft, eccentricity, loosening of the locking
bolts, depletion of oil, etc.

- Check for play (looseness of bolt) in the shaft, keys and


couplings

- Check for abnormal noise in the gears, reduction gears, etc.

- Is oiling of the gears and reduction gears appropriate, and is


any heat being generated?

5. Tentative autonomous standards - Have tentative inspection standards been prepared?


inspection

- Have improvements been made to reduce the number of


inspection items?

- Have improvements been made to make inspection easier ?

- Are the inspection methods and period appropriate?

- Are means being devised so that inspection is performed


steadily and without omissions?

AM 4-3step diagnosis sheet JIPM


Step 4 Diagnosis Sheet

Application Form for Autonomous


Section/ team name Application date Section Manager Leader
Maintenance Diagnosis
Autonomous Maintenance Diagnosis Assembly line to be
Sheet diagnosed

Desired diagnosis __/__/__


___Points Pass Fail
date
Step 4-4: General Inspection
(Electrical) Diagnosis date __/__/__
Pass level
and time __:__ - __:__ ( of level points in items 1 - 6)
Diagnosis Autonomous Section Manager Top Executive Diagnosed by
Autonomous Section Manager Top Executive

90 points or 85 points or 80 points or


more more more

Bad Poor Fair Somewhat good Good


Diagnosis item Points of diagnosis Suggestions

20 points 40 points 60 points 80 points 100 points


Maintenance and control (Are operation and maintenance being performed for 1-3?)
- Are countermeasures for generating sources being adequately
maintained?
- Are the improvement conditions satisfactory for
countermeasures for difficult-to-access cleaning locations?
- have cleaning and oiling standards been completed, and are
they being utilized accordingly?

1 point 2 points 3 points 4 points 5 points


1. Skill education - Are Leaders and Circle Members actively creating one-point
textbooks and raising their level of skill?

- Have all members mastered general inspection skills?

2. General inspection - Are the items of education steadily being inspected?

- Are problem locations being identified through inspection?

- Are countermeasures being taken for locations where


problems were identified?

3. Safety - Are minor defects related to safety being identified, and are
countermeasures being taken?

4. Site Diagnosis - Are the indicator plates attached to the electrical


(electrical) distribution, control and operation panels?

- Is the temperature of the electrical distribution, control and


operation panels high?

- Are the electrical distribution, comtrol and operation panels


dirty (water, oil and waste)?

- Check for dirt and damage in the cover packing and filters of
the electrical distribution, control and operation panels

- Check for abnormalities (overheating, damage, unstable


wiring) in the wiring and connections

- Check for overheating, abnormal noise and vibration in the


motors

- Are sensors properly installed (position contact and


looseness)?

- Is the sensor dirty (water, oil and waste)?

- Check for sensor breakage.Check the mounting condition of


the lead wires. Are measures being taken to prevent breakage?

5. Tentative autonomous standards - Have tentative inspection standards been prepared?


inspection

- Have improvements been made to reduce the number of


inspection items?

- Have improvements been made to make inspection easier ?

- Are the inspection methods and period appropriate?

- Are means being devised so that inspection is performed


steadily and without omissions?

AM 4-4step diagnosis sheet JIPM


Step 4 Diagnosis Sheet

Application Form for Autonomous


Section/ team name Application date Section Manager Leader
Maintenance Diagnosis
Autonomous Maintenance Diagnosis Assembly line to be
Sheet diagnosed

Desired diagnosis __/__/__


___Points Pass Fail
date
Step 4-5: General Inspection
(Nuts and bolts) Diagnosis date __/__/__
Pass level
and time __:__ - __:__ ( of level points in items 1 - 6)
Diagnosis Autonomous Section Manager Top Executive Diagnosed by
Autonomous Section Manager Top Executive

90 points or 85 points or 80 points or


more more more

Bad Poor Fair Somewhat good Good


Diagnosis item Points of diagnosis Suggestions

20 points 40 points 60 points 80 points 100 points


Maintenance and control (Are operation and maintenance being performed for 1-3?)
- Are countermeasures for generating sources being adequately
maintained?
- Are the improvement conditions satisfactory for
countermeasures for difficult-to-access cleaning locations?
- have cleaning and oiling standards been completed, and are
they being utilized accordingly?

1 point 2 points 3 points 4 points 5 points


1. Skill education - Are Leaders and Circle Members actively creating one-point
textbooks and raising their level of skill?

- Have all members mastered general inspection skills?

2. General inspection - Are the items of education steadily being inspected?

- Are problem locations being identified through inspection?

- Are countermeasures being taken for locations where


problems were identified?

3. Safety - Are minor defects related to safety being identified, and are
countermeasures being taken?

4. Site Diagnosis - Check for looseness of nuts and bolts


(Nuts and bolts)

- Check for defects and breakage of nuts and bolts

- Are measures being taken to lock nuts and bolts where needed?

- Are plain washers being used in slots?

- Are the lengths of bolts appropriate?

- Are matching marks inscibed in nuts and bolts subject to vibration?

- Are uniform bolts, nuts and washers being used in the same mounting
locations?

- Are Jigs and tools, such as spanners, organized in easy-to-use positions


(indicated positions)?

- Are means being devised and improvements being made to make nuts
and bolts in frequently used locations easy to attach and remove?

5. Tentative autonomous standards - Have tentative inspection standards been prepared?


inspection

- Have improvements been made to reduce the number of


inspection items?

- Have improvements been made to make inspection easier ?

- Are the inspection methods and period appropriate?

- Are means being devised so that inspection is performed


steadily and without omissions?

AM 4-5step diagnosis sheet JIPM


Step 5 Diagnosis Sheet

Subsection Section TPM Autonomous Maintenance Step 5 Diagnosis date: __/__/__ General inspection Try again
Department Diagnosed by __/100 points Pass
Autonomuos Inspection Diagnosis Sheet
Target equipment: 80 points or more

Diagnosis Point Evaluation Points


Are the steps up until now being mantained Improved remarkably Improved somewhat Mantained as when Passably Below the level when Level has regressed
since passing steps since passing steps passed passed
6 5 4 3 2 1
Status of follow-up for Have improvements been nade for problem points identified in previous diagnoses? All have been Most have been Passably Could do better Not yet No improvement
Steps 1-4 improved improved
6 5 4 3 2 1

Comments ___ / 12 points

Diagnosis Point Evaluation Points


Are necessary inspection items being omitted "for reasons of inability?" No blind spots No omissions for the Could do better Not yet
most part
4 3 2 1
Details of autonomus Are inspection items specific to the equipment being included? Not yet Not included
Included without Included for the most
inspection Inspection
exception part
items
4 3 2 1
Have periodic inspections been coordinated with the Engineering Section? Appropriate Could do better Not yet Not coordinated
coordination
3 2 1 0

Comments ___ / 12 points

Diagnosis Point Evaluation Points


In cases where there are many inspection items, are they divided up to make implementation easier?
Appropriately divided Decided Not yet Indeterminate

Purpose 4 3 2 1
Are standards set so that the period of inspection can be observed? Can be observed Could do better Not yet Not possible
4 3 2 1
Are means devised for "visual" management to make inspection can be observed? Means devised for
Through general Could do better Not yet No means devised
visual inspection
inspections, steadily Ease of 4 3 2 1
maintain conditions that inspection Is the sequence of inspections arranged to make inspections easy to perform? Appropriately
restore deterioration For the most part Not yet Not sequenced
sequenced
4 3 2 1
Can be performed in the allotted time? Can be performed
within the allotted For the most part Not yet Completely impossible
time
Improve the efficiency
of cleaning, inspection 4 3 2 1
and oiling through
devising means for
visual inspection Comments ____ / 20 points

Diagnosis Point Evaluation Points


With regard to predetermined items, Well incorporated Incorporated for the Not yet Not incorporated
(a) Is inspection incorporated for Quality (Q)? most part
Reevaluate the role of 4 3 2 1
equipment and people, Quality related
(b) Is the check for weighing equipment, measuring equipment, detection equipment and misoperation prevention Thorough Passably Could do better Poor
and clarify what an items
equipment satisfactory? 4 3 2 1
abnormal condition is
(c) Are proper accuracy checks of equipment and tools for checking processes being kept? Well defined Defined Passably Not defined
4 3 2 1

Comments ___ / 12 points


Make improvements so
that equipment has good Diagnosis Point Evaluation Points
operationality Are inspections being carried out in accordance with inspection standards, and are records being kept? Through inspection Inspection and Could do better No record keeping
and record keeping record keeping are
being performed for
the most part

Implementation 4 3 2 1
status of
Are improvements being made for problem points identified as a result of inspections? Thoroughly improved Improved for thr Could do better No improvement
inspections
most part
4 3 2 1
Are areas of deterioration being reliably identified and handled as a result of inspection cleaning? Reliably identified Identify for the most Could do better Not yet stardted
part
4 3 2 1

Comments ___ / 12 points

Diagnosis Point Evaluation Points


To devise means for raising the level of inspection skills, Well incorporated Incorporated for the Not yet Not incorporated
(a) Are the weak points of inspection skills understood? most part
Skill of
4 3 2 1
inspection
(b) Are ther plans for that training and education? Well defined Defined Passably Not defined
4 3 2 1

Comments ___ / 8 points

Diagnosis Point Evaluation Point


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

Comments ____ / 24 points

AM 5step diagnosis sheet JIPM


Step 6 Diagnosis Sheet

Subsection Section TPM Autonomous Maintenance Step 6 Diagnosis date: __/__/__ General inspection Try again
Department Diagnosed by __/100 points Pass
Order and Arrangement Diagnosis Sheet
Target equipment: 80 points or more

Diagnosis Point Evaluation Point


Are the conditions at the time of passing previous steps being maintained? Improved since passing Maintained as when Passably Below the level when
Maintenance and control steps passed passed
activities 3 2 1 0
Have improvements and measures been taken for items cited at previous diagnoses? All have been improved or Improved for the most Low rate of Problems with maintaining
are scheduled to be part implementation autonomous maintenance
improved
3 2 1 0
Is autonomous maintenance being steadily implemented, and are standards being reevaluated as needed? Steadily implemented and Reevaluation could be Inadequate Problems with mainaining
(Status of follow-up thoroughly established better implementation autonomous maintenance
on Steps1-5) 4 3 2 0
Has the maintenance (cleaning, oiling and retightening) of basic conditions been established? Establish and maintained Standards are being Could do better Still inadequate
in good condition observed for the most
part
3 2 1 0
Do the 5S of workplace improve? Extremely good Passably Could do better Still inadequate
3 2 1 0

Comments ____ / 16 points

Diagnosis Point Evaluation Point


Are check-sheets being used, and is inspection work being carried out steadily? Inspection work is well Being implemented Could do better Inadequately
Order and arrangement understood
"Equipment" 3 2 1 0
Are quality control items incorporated in the inspection items, and does this lead to a reduction in defects? Leads to good results Incorporated Items are understood but Items are not understood
not incorporated
3 2 1 0
Are equipment problems handled speedily and reliably? Handled reliably Passably Could do better Inadequately
3 2 1 0

(Make firms decisions Is visual management thoroughly implemented, and have means been devised so that anyone can determine visually whether there Thoroughly implemented, Can be visually Cannot be understood Not making progress
and steadily observe is a problem? and anyone can determine determined for the most without explanation
them) problems part

4 3 2 0
Are the number of inspection items being reduced, and is the introduction of predictive maintenance making progress? Making good progress Making partial progress Ubder consideration Not making progress
3 2 1 0
Are standards set for routine checking of detection and control equipment, and are their functions being verified? There are standards and Implemented in Could do better Still inadequate
they are firmly accordance with
Inspection of
established standards for the most
equipment
part
accuracy
3 2 1 0

Comments ____ / 19 points

Diagnosis Point Evaluation Point


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

Through Are things that are infrequently used managed centrally in one location? Throughly managed Basically centralized Some parts remain to be Inadequately
visual management centralized
3 2 1 0
Are things in a state that allow them to function adequately? In good condition without Passable condition Could do better Inadequately
any breakage or dirt

4 3 2 0

Comments ____ / 22 points

Diagnosis Point Evaluation Point


Order and arrangement Are the various standards being reevaluated and properly ordered? Ordered and in operation Nearly completed Steel being reevaluated Will start from now on
"Personnel"
3 2 1 0
Have correct operation procedures, work requirements for handling, and standards for work been created? Have been created and Have been created for Working on it not created
are being observed the most part
3 2 1 0
(Are the operator's
Are education and training being conducted for priority items related to operation procedures and quality, and are skills being Systematically Carried Plan is completed Planning in progress Not yet
duties clearlydefined,
evaluated? out
and are those duties
3 2 1 0
being carried out?)
Is work being performed according to standards, and is the work going well? Without difficulty Good for the most part Could do better Not yet
3 2 1 0
When failures or quality defects occur, is each case analyzed one at a time and are efforts made to prevent recurrence? Properly analyzed Generally analyzed Could do better Inadequately
3 2 1 0
Through Are the method for handling problems decided, and are they observed? Throughly decided and Generally satisfactory Partially not yet decided Inadequately
standardization observed
3 2 1 0
Are records being properly kept, and are they organized and stored? Properly implemented Generally satisfactory Could do better Inadequately
3 2 1 0

Comments ____ / 24 points

Diagnosis Point Evaluation Point


Looking at the activities board, are the activity details and results, prevention of future recurrence of problems, and future Contents of activities can Basically understood Not yet linked Contents are unclear
Group activities plans properly linked be seen at a glance
3 2 1 0
Is the focus of improvement set as a group, and are all group members involved? All group members are Focus is set and effort There is a focus but The focus is unclear
involved and results are are underway efforts are inadequate
being obtained
3 2 1 0
Are meetings lively and conducted as planned? Five or more times a Three or more times a Two or fewer times a Meetings hardly held at
month, and very lively month, and lively month, and could do all
better
3 2 1 0
Based on the concept of "learning from failures and quality defects," are one-point lessons being written up and are Extremely good Good Could do better Not yet
(are all members of the countermeasures being taken? 3 2 1 0
group actively
Are improvement suggestions being actively submitted, and are all members reaching their goals and improving their Six or more suggestions/ Four or more Two or more suggestions/ Under two suggestions/
participating and are
performance? person-month, and very suggestions/ person- person-month, and could person-month, and
results being obtained?)
lively month, and satisfactory do better inadequate activity
activity
3 2 1 0
Is daily management established in order to raise production efficiency? Daily management is Handling of this is Awareness of daily Inadequately
established and slightly weak management is isufficient
satisfactory
3 2 1 0
Do all personell understand the meaning of 5S, and is this apparent in their behavior? Extremely good Good Could do better Inadequately
3 2 1 0

Comments ____ / 21 points

AM 6step diagnosis sheet JIPM