Safety, Health,

Environmental
TPM in Administration
Quality Maintenance
Total Preventative Maintenance

Early Management
5S

Education and Training

Effective Maintenance
Focussed Improvement
Autonomous Maintenance
Step 0 and 1 (Part 1)
Autonomous Maintenance

Program Initiation
Definition: A structured approach that establishes a corporate culture, that
will maximize production system effectiveness.

Total Involvement of all functions and

people at all levels of organization. The Aim is to prevent losses and achieve:
Productive Efficient and effective utilisation Zero Accidents.
of all resources. Zero Defects.
Maintenance Keeping the man-machine- Zero Breakdowns.
material system in optimal condition.
Jishu Hozen means activities of the Production Team Member that uses
maintenance to personally conduct maintenance activities such as cleaning,
oiling, retightening and inspecting.

Jishu Hozen represents activities that eliminate equipment

failures; minor stoppages; defects and losses by maintaining,
improving and restoring equipment to desirable forms.

The activities will prevent forced

deterioration of equipment, resulting in
increased production efficiency.
The Goal of Jishu Hozen is to develop operators to:

Follow uniformity in
Maintain Become
implementing shop floor
equipment expert
activities to eliminate
and work equipment
forced deterioration on
places. operators.
equipment.

The Jishu Hozen is a step-by-step methodology for making the equipment

as it should be.

Jishu Hozen has seven steps. The focus today is on Step 0 - 1, which is
conduct initial cleaning and inspection.
Jishu Hozen brings significant change to the I Manufacture You Repair or
I Make You Fix to I Make I Manage.

Operators and Maintenance collaborate to ensure that the equipment is

completely healthy.
 Production Team Members conduct activities to eliminate forced deterioration.

Work Together with Maintenance, eventually saving maintenance time to conduct

Planned Maintenance activities.

Forced deterioration Force deterioration

is due to will occur if machines
abnormalities. are not taken care of.

The Production Team Members must implement the following activities:

Improvement of basic conditions of equipment such as Cleaning,

Lubricating, Retightening and Inspection.

Adjustments such as adjustment in operation and setting up

prevention of quality defects.
Grease hiding abnormalities
Prediction and early detection of abnormalities.
 Recording
maintenance
data to ensure
feedback for
prevention of
recurrence.

Routine
Assist in
inspection on
sporadic repair.
the equipment.

Minor
Speedy improvements
notification of such as
failures and replacing parts
malfunctions. during
abnormalities.
 Attention of the Team Member is diverted onto the equipment.
1S is Sorting the Workplace
Tools that are kept around the equipment are classified into
necessary and unnecessary items. The sorting activity has to be
done by operators under the guidance of Supervisors or
Management.
Decision Matrix for Sorting out Tools.
 Frequency of
Priority How to Use?
Use?

Throw away.
Less than once
Low Store away from
per Year.
the workplace.

At least Once Store together

Average
per Month but Off-line.

Locate at the
High Once per Day.
Workplace.

Before and After Clearing area

 The fundamental principle is

Everything has place and everything in its place

2S is Organising the Workplace

Assign each Item with a label.

Decide the right place for each necessary item, ensuring easy accessibility.
Mark the locations.

Draw a boundary around the

equipment/items to indicate its zone.

Exhibit the status clearly e.g. Tool Change.

The Advantages of 1S and 2S are:

Clean and efficient work place will be

created and shop floor housekeeping will
be of highest order.
Movement of Team Member will be
minimized.
Time spent searching for necessary items
are eliminated.
Safer working conditions ensured.
Increased productivity.
Form a cross-functional team comprising of shift operators, maintenance staff, office
staff and supervisors. All Team members need to know the meaning of
Abnormalities.
Initial cleaning materials required before commencing
with Step 1:
White and Red tags, brushes, rags, cleaning
solvent, gloves, torchlight, cable ties and tool box.

All Team Members briefed on the Safety aspects of

equipment before cleaning.

Video and photographs captured before and after

Management and workforce
initial cleaning. working together as a team, showing
commitment to program
Audits are carried out to ensure the achievement of success of each step. Audits are carried out
in three stages by the:
Team who had carried out the activity.
Manager of the area.
Unit head along with the TPM Secretariat.
The equipment should get at least 80 points during the Unit head audit. Thereafter, the next step
may commence.

The benefit is the operator is carrying out the

Important tasks and finding issues with the aim of
Bringing the equipment to As New