TPM Autonomous Maintenance Audit Guide & Checklists

© Operational Excellence Consulting. All rights reserved.© Operational Excellence Consulting. All rights reserved.
This is a set of Autonomous Maintenance audit step-by-step checklists
based on the TPM Excellence Framework. The audit tool is in Microsoft
Oﬃce Excel format and can be tailored to suit your industry and
machine or equipment.
TPM Autonomous Maintenance
Audit Guide & Checklists

© Operational Excellence Consulting. All rights reserved. 2
About the TPM AM Audit Checklists
§  This is a set of Autonomous Maintenance audit step-by-step
checklists based on the TPM Excellence Framework. It consists of 6
checklists covering steps 1 to 6 of the AM pillar.
§  The AM audit checklists are especially useful for companies who
want to kick-start the AM implementation process.
§  The AM audit checklists are in Microsoft Office Excel format and can
be easily tailored to suit your industry and machine or equipment
type.
§  The audit tool is quite comprehensive and users may simplify the
checklist items and/or the evaluation points to the level that your
TPM teams and auditors are comfortable with.

Objectives
By the end of the TPM Autonomous Maintenance
evaluation, you will be able to:
1.  Acquire a deep understanding of each step of the AM pillar for TPM
excellence
2.  Define the AM step-by-step audit areas and evaluation points
3.  Conduct a systematic AM step-by-step audit for each equipment
and identify areas for improvement
4.  Establish a baseline position so you can measure your progress
over time
NOTE: This is a PARTIAL PREVIEW. To
download the complete presentation, please
visit: http://www.oeconsulting.com.sg

Contents
1.  Overview of the 7 Steps of AM
2.  AM Audit Items & Evaluation Points
3.  Anatomy of an AM Audit Checklist
4.  Customizing the AM Audit Checklist
5.  How to Conduct an AM Audit

© Operational Excellence Consulting. All rights reserved.
5
Overview of the 7 Steps of AM
1

The 7 Steps of Autonomous Maintenance
Steps of AM Main Objective
1. Clean and inspect
To keep the state of the equipment from
deteriorating
2. Eliminate problem sources and
inaccessible areas
3. Draw up cleaning and lubricating
standards
4. Conduct general inspections
General inspection standards to
complement the first 3 steps
5. Conduct autonomous inspections
6. Standardize through visual workplace
management
Focus on the entire work area
7. Implement autonomous equipment
management
Independent maintenance activities as
part of business as usual

7
AM Audit Items & Evaluation
Points
2

AM Step 3 Audit (Partial Checklist)
Step 3 Audit Sheet
Subsection Section TPM Autonomous Maintenance Step 3 Audit date:__/__/__
General inspection
__/100 points
Try again
Department
Audit Sheet for Creating Cleaning and Lubrication Standards Audited by
Pass
Target equipment:
80 points or more
Step 1
Maintenance and
improvement of conditions
when initial cleaning step
was passed
Purpose:
Definition of baseline
conditions
Audit Point Evaluation Points
Are clean conditions being maintained?
Cleaner than when
passed
Maintained as when
passed
Passably
Below the level when
passed
Dirty
5 4 3 2 1
Are Cleaning and Inspection being observed, are problems being identified?
Being identified Cleaning is inspection Could do better Marking time Regressing
5 4 3 2 1
Are workers identifying problems with greater details, and is the next step after improving the skills of members understood?
Skills improved
remarkably
Skills improved Greater detail No change in details Lesser detail
5 4 3 2 1
Comments
___ / 15 points
Step2
Status of follow up on
generating sources, difficult
to access cleaning and
lubrication locations, and
countermeasures
Purpose:
Improve reliability and
maintainability
Are the improvements being made to lubrication and are these improvements leading to increased maintainability?
Maintainability is improved Could do better Oiling improved Not yet No improvement
5 4 3 2 1
Are plans being drafted again for those items which did not achieved adequate results from the countermeasures?
Meticulously planned Plan drafted
Drafting of plan in
progress
Drafting of plan scheduled Not yet started
5 4 3 2 1
Are further measures needed? (are any omissions in the countermeasures?)
No blind spots
Almost completely
unneeded
Could do better Not yet Greatly needed
4 3 2 1 0
Comments
___ / 14 points
Details of cleaning and
inspection standards
Purpose:
Maintenance and control of
cleaning and inspection
Where? Has the range of the division of oil responsibilities been decided? Firmly decided Decided Passably Not decided
Who? 4 3 2 1
By what method? Are the methods and tools for cleaning and inspection decided? Firmly decided Decided Passably Not decided
4 3 2 1
When? Are the period and time for cleaning and inspection set appropriately? Set appropriately Could do better Not yet Not decided
How much? 4 3 2 1
What? Is the object of cleaning and inspection clarified? Clarified Could do better Not yet Not decided
4 3 2 1
Is the cleaning status recorded on check-sheets, and is this consciously observed?
Observance of this
procedure can be seen
visually
Could do better
Procedure is observed,
but not clearly
Not recorded
4 3 2 1
Comments
____ / 20 points

AM Step 6 Audit (Partial Checklist)
Step 6 Audit Sheet
General inspection
__/100 points
Try again
Department
Order and Arrangement Audit Sheet Audited by Pass
Target equipment:
80 points or more
Maintenance and Control
Activities
(Status of follow-up
on Steps1-5)
Audit Point Evaluation Point
Are the conditions at the time of passing previous steps being maintained?
Improved since passing
steps
Maintained as when passed Passably
Below the level when
passed
3 2 1 0
Have improvements and measures been taken for items cited at previous diagnoses?
All have been improved or
are scheduled to be
improved
Improved for the most part Low rate of implementation
Problems with maintaining
autonomous maintenance
3 2 1 0
Is autonomous maintenance being steadily implemented, and are standards being reevaluated as needed?
Steadily implemented and
thoroughly established
Reevaluation could be better Inadequate implementation
Problems with mainaining
autonomous maintenance
4 3 2 0
Has the maintenance (cleaning, oiling and retightening) of basic conditions been established?
Establish and maintained in
good condition
Standards are being
observed for the most part
Could do better Still inadequate
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
Order and Arrangement
"Equipment"
(Make firm decisions and
steadily observe them)
Inspection of
equipment
accuracy
Audit Point Evaluation Point
Are check-sheets being used, and is inspection work being carried out steadily?
Inspection work is well
understood
Being implemented Could do better Inadequately
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 not
incorporated
Items are not understood
3 2 1 0
Are equipment problems handled speedily and reliably?
Handled reliably Passably Could do better Inadequately
3 2 1 0
Is visual management thoroughly implemented, and have means been devised so that anyone can determine visually whether there is a problem?
Thoroughly implemented,
and anyone can determine
problems
Can be visually determined
for the most part
Cannot be understood
without explanation
Not making progress
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
they are firmly established
Implemented in accordance
with standards for the most
part
Could do better Still inadequate
3 2 1 0
Comments
____ / 19 points

10
Anatomy of an AM Audit
Checklist
3

Anatomy of AM Audit Checklist
Step 3 Audit Sheet
General inspection
__/100 points
Try again
Department
Audit Sheet for Creating Cleaning and Lubrication Standards Audited by Pass
Target equipment:
80 points or more
Step 1
Maintenance and
improvement of conditions
when initial cleaning step
was passed
Purpose:
Definition of baseline
conditions
Are clean conditions being maintained? Cleaner than when passed Maintained as when
passed
Passably Below the level when
passed
Dirty
5 4 3 2 1
Are Cleaning and Inspection being observed, are problems being identified? Being identified Cleaning is inspection Could do better Marking time Regressing
5 4 3 2 1
Are workers identifying problems with greater details, and is the next step after improving the skills of members understood? Skills improved remarkably Skills improved Greater detail No change in details Lesser detail
5 4 3 2 1
Comments
___ / 15 points
Evaluation PointsAudit Items
Area for comments

12
Customizing the AM Audit
Checklist
4

Customizing the Checklist
§  The set of audit checklists provided are designed for a
manufacturing environment and are quite comprehensive.
§  To make the checklists more relevant to your industry or company,
the audit items and evaluation points for each step of AM should be
tailored to suit your specific industry or machine/equipment.
§  If your organization has just started on the TPM journey, you may
simplify the checklists (so as not to scare the TPM teams and
auditors) initially and then review later if additional audit items
should be added or refined as you gain more practical experience
from the audit activities.

Customizing the Audit Items
§  The AM audit checklists are not meant to be prescriptive and you
may tailor them to a level that the auditors and the TPM teams are
comfortable using them.
§  As an option, you may adopt the ECRS approach to customize the
checklists:
–  Eliminate the audit items that are not relevant to your equipment
–  Combine two or more audit items and group them into just one item
–  Reduce the number of audit items
–  Simplify the audit items
§  Do note that you may need to redistribute the evaluation points to
maintain the 100-point score for the AM step. Alternatively, convert
the score to percentage instead.

15
How to Conduct an AM Audit
5

How to Conduct an AM Audit
1.  The audit checklists consist of two main columns:
a.  Audit Items/Points (in yellow)
b.  Evaluation Points (in green).
2.  Each audit item/point is to be evaluated over its corresponding
evaluation scale. Use the point descriptors to help you decide
which score best represents the current audit status.
3.  Write down any observed strengths, weaknesses or evidences
under the ‘Comments’ area. The information should be helpful for
the auditee teams to develop improvements plans.
4.  Add up all the points for the step audit and write the total score on
the top right of the audit sheet. The maximum possible score is
100 points.

Auditing as a Team
1.  Instead of a single auditor, the AM step audit can also be done by a
team of auditors. The team can be formed by auditors from other
production areas and may include leaders, supervisors or
managers.
2.  A copy of the step audit sheet should be given to each member of
the audit team.
3.  The audit team will need to convene one or more planning
session(s) to decide on the procedures and schedule for carrying
out the audit activity.
4.  They may need to review the audit checklist to identify the basic
information that needs to be gathered to facilitate the audit process.

Writing the Strengths & Areas for Improvement
1.  For each group of audit items, write down the strengths and areas
for improvement under the ‘Comments’ area.
2.  The strengths identified should relate to the top scoring 1-2
evaluation boxes.
3.  Similarly, the areas for improvement identified should be related to
the lowest 1-2 audit items.

About Operational Excellence
Consulting
§  Operational Excellence Consulting is a management training and
consulting firm that assists organizations in improving business
performance and effectiveness.
§  One of our unique strengths is going beyond a tools-focused
approach to seamlessly integrate people, processes, technology
and continuous improvement initiatives to suit the specific needs
and situations of our clients.
§  We provide corporate learning programs and management advisory
services to assist our clients to achieve breakthrough in business
performance and effectiveness. Our aim is to support our clients in
designing, managing and executing lasting beneficial change.

END OF PREVIEW
To download this presentation,
please visit:
www.oeconsulting.com.sg

TPM Autonomous Maintenance Audit Guide & Checklists

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