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Autonomous Maintenance (AM) Checklist
Autonomous Maintenance (AM) Checklist
SafetyCulture Staff

Autonomous Maintenance (AM) Checklist

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Free Autonomous Maintenance (AM) Checklist Checklist

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Title Page

  • Area / Team

  • Equip. Unit No.

  • Date requested for review

  • Actual date / Time of review

  • Name of reviewer

  • Submission date

  • Area manager

  • Team leader

  • Review type

  • Location

Step 1: Initial Cleaning (Processing Equipment)

  • Pass levels :Score = total score for ‘equipment’ (Review Items 1-5) + score for ‘people’ (Review Item 6)

    Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

    step 1.PNG

  • Result

    • Pass
    • Fail

1. Cleanliness of main body of equipment

  • Dust, dirt, oil stains and waste all cleaned off, and materials and tools put neatly in order (jigs, chucks, sliding parts, chutes, frames, beds, pipes, wires, etc.)?

  • Looseness, play, vibration, friction and overheating eliminated (nuts, bolts, jigs, rotating and sliding parts, chutes, etc.)?

2. Cleanliness of peripheral apparatus

  • - Hydraulic, pneumatic, and water systems
    - Electrical control systems
    - Other

  • Dust, dirt, oil stains and debris all cleaned off (cylinders, solenoids, FRLs, motors, limit switches, belts, proximity switches, photocells, control panel

  • Interiors/exteriors, meters / gauges, etc.)?

  • Looseness, play, vibration, friction, buzzing and overheating eliminated (motors, solenoids, limit switch mounting plates, relays, wires, nuts, bolts, etc.)?

3. State of lubrication

  • Dust, dirt and oil stains all cleaned off (lubricators, oil pumps, level gauges, filler caps, supply pipes, etc.)?

  • Oil volumes and drip rates correct, and looseness, play, and vibration eliminated (contamination/degradation of oil itself, pipe joints, valves, gearboxes, oil temperature, etc.)?

4. Cleanliness of equipment surroundings

  • - Tools, measuring instruments, and spare parts all organised correctly?<br>- Guards, nameplates, labels, and other signs all displayed correctly?<br>- Unnecessary objects removed, and correct products and parts kept in correct places?

  • - Defective products clearly separated from good ones?<br>- Aisles clear and tidy?<br>- No scattering of dust/dirt from other equipment?

5. Contamination sources and hard- to- access areas

  • Chart drawn up plotting all sources of dirt, dust and oil stains, and areas that are hard to clean? Plan formulated for dealing with these?

  • - Improvements made to guards and cleaning tools?<br>`Checking through cleaning' being implemented?<br>- Cleaning areas clearly allocated?

6. Way in which TPM is being addresse

  • Do all team members have a good understanding of what TPM means, and are they all fully involved in implementing it?

Step 2: Contamination Sources and Hard-to-Access Areas(Processing Equipment)

  • Pass levels :Score = total score for Review Items 1- 6

    Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

    step 2.PNG

  • Result

    • Pass
    • Fail

1. Sustainment of Step 1

  • - Cleaning levels achieved in Step 1 (Initial Cleaning) being properly sustained?

2. Countermeasures for main body of equipment

  • -Sources of dirt, dust, oil leaks, air leaks, etc. all plotted on a chart, and action taken to rectify them?

  • -Hard-to-access areas all marked on a chart, and creative improvements implemented to make them more accessible (guarding improved, original cleaning tools devised, everything sorted and reorganised)?

3. Countermeasures for peripheral devices

  • - Sources of dirt, dust, oil leaks, air leaks, etc. all plotted on a chart, and action taken to rectify them?

  • - Hard- to- access areas all marked on a chart, and creative improvements implemented to make them more accessible (guarding improved, original cleaning tools devised, everything sorted and reorganised)?

4. Countermeasures for equipment surroundings

  • - Sources of dirt, dust, oil leaks, air leaks, etc. all plotted on a chart, and action taken to rectify them?

  • - Hard- to- access areas all marked on a chart, and creative improvements implemented to make them more accessible (guarding improved, original cleaning tools devised, everything sorted and reorganised)?

5. Improvement and sustainment

  • - Lubrication points clearly labelled according to lubrication standards, so that anyone can lubricate the machines correctly?

6. Status of activities

  • - All team members actively involved?

  • - Plenty of original thought going into the improvements?

Step 3: Provisional Autonomous Maintenance Standards (Processing Equipment)

  • Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

  • Result

    • Pass
    • Fail

1. Sustainment of Steps 1 and 2

  • - Cleaning levels achieved in Step 1 (Initial Cleaning) and improvements made in Step 2 (Contamination Sources and Hard- to- Access Areas) being properly sustained?

2. Maintenance of basic equipment conditions (action standards for cleaning, lubricating and tightening)

  • (Cleaning Standards)

  • - Separate standards created for each equipment unit, area, etc.?

  • - Cleaning areas, locations and work duties properly defined and allocated?

  • - Cleaning methods and tools specified?

  • - Suitable cleaning times and intervals set and observed?

  • - Standards clear enough for anyone to follow?

  • (Lubrication Standards)

  • - Type and quantity of oil, frequency of lubrication, method and responsibilities all clearly specified?

  • - All lubrication points correctly labelled?

  • - Required lubricants always available?

  • - Lubricants stored neatly and systematically (lubricant storage areas clean and tidy)?

  • (Tightening)

  • - Nuts and bolts all correctly tightened?

  • - Any nuts and bolts missing?

3. Awareness of role in creating standards

  • - Teams setting their own standards?

  • - Standards being observed?

  • - Improvements actively pursued to make checking easier and enhance visual management?

Step 4-1: General Inspection (Fastenings)

  • Pass levels :Score = total score for Review Items 1- 6

    Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

  • Result

    • Pass
    • Fail

Sustainment

  • Steps 1 to 3 activities properly managed and sustained?)<br>- Action against contamination sources being properly sustained?<br>- Good improvements making hard- toaccess areas more accessible?<br>- Cleaning and lubrication standards completed and applied rigorously?

1. Skills Training

  • - Leaders and team members actively creating OPLs and compiling them into manuals to upgrade their skills?

  • - General Inspection skills mastered by all team members?

2. General Inspection

  • - Inspection done correctly, covering all items in category trained?

  • - Minor equipment problems identified reliably during inspection process?

  • - Action taken to deal with these problems?

3. Safety

  • - Progress made in identifying and fixing minor equipment problems that compromise safety?

4. Shop- floor review (Fastenings)

  • - All nuts and bolts, etc. correctly tightened?

  • - Any nuts or bolts missing or damaged?

  • - Countermeasures against loosening (locknuts, etc.) introduced where necessary?

  • - Flat washers used for oval holes?

  • - Bolts of suitable length used?

  • - Matchmarks inscribed on nuts and bolts susceptible to vibration?

  • - Same kinds of nuts, bolts, washers, etc. used in same kinds of locations?

  • - Spanners and other tools located and arranged for easy use (marked location for each tool)?

  • - Regularly- used fastenings improved for easy installation and removal??

5. Provisional Autonomous Maintenance standards

  • - Provisional checking standards completed?

  • - Improvements made to reduce number of checks required?

  • - Improvements done to make checks easier to carry out?

  • - Suitable checking methods and checking intervals adopted?

  • - Ways found to ensure that all checks are done reliably, without any being omitted?

Step 4- 2: General Inspection (Lubrication)

  • Pass levels :Score = total score for Review Items 1- 6

    Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

  • Result

    • Pass
    • Fail

Sustainment

  • Steps 1 to 3 activities properly managed and sustained?)<br>- Action against contamination sources being properly sustained?<br>- Good improvements making hard- toaccess areas more accessible?<br>- Cleaning and lubrication standards completed and applied rigorously?

1. Skills Training

  • - Leaders and team members actively creating OPLs and compiling them into manuals to upgrade their skills?

  • - General Inspection skills mastered by all team members?

2. General Inspection

  • - Inspection done correctly, covering all items in category trained?

  • - Minor equipment problems identified reliably during inspection process?

  • - Action taken to deal with these problems?

3. Safety

  • - Progress made in identifying and fixing minor equipment problems that compromise safety?

4. Shop- floor review (Lubrication)

  • - Lubrication points correctly and clearly labelled, with effective systems for ensuring that none is missed out?

  • - Correct lubricant types being used?

  • - Correct amounts of lubricant being used?

  • - Lubricants clean and not degraded?

  • - All lubrication pipes unblocked and undamaged?

  • - Lubricants always available when needed?

  • - Different lubricators, oil cans, etc. used for different types of lubricant?

  • - All grease nipples and lubricators undamaged and free of dust and dirt?

  • - Different lubricant types separated and arranged systematically in lubrication stations? Lids always kept on containers? Stations appropriately located and free from dust and dirt?

5. Provisional Autonomous Maintenance standards

  • - Provisional checking standards completed?

  • - Improvements made to reduce number of checks required?

  • - Improvements done to make checks easier to carry out?

  • - Suitable checking methods and checking intervals adopted?

  • - Ways found to ensure that all checks are done reliably, without any being omitted?

Step 4- 3: General Inspection (Drives)

  • Pass levels :Score = total score for Review Items 1- 6

    Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

  • Result

    • Pass
    • Fail

Sustainment

  • Steps 1 to 3 activities properly managed and sustained?)<br>- Action against contamination sources being properly sustained?<br>- Good improvements making hard- toaccess areas more accessible?<br>- Cleaning and lubrication standards completed and applied rigorously?

1. Skills Training

  • - Leaders and team members actively creating OPLs and compiling them into manuals to upgrade their skills?

  • - General Inspection skills mastered by all team members?

2. General Inspection

  • - Inspection done correctly, covering all items in category trained?

  • - Minor equipment problems identified reliably during inspection process?

  • - Action taken to deal with these problems?

3. Safety

  • - Progress made in identifying and fixing minor equipment problems that compromise safety?

4. Shop- floor review (Drives)

  • - V- belts unworn and in good condition? Pulleys unworn and properly centred?

  • - V- belts correctly tensioned?

  • - Visual controls introduced on V- belt covers to indicate direction of rotation, belt specifications, etc.?

  • - Lubricating oil penetrating fully between pins and bushes on chains?

  • - Chains unstretched and properly centred? Chains free of meshing problems due to worn sprockets?

  • - Bearings free of overheating, vibration or strange noises due to bent or off- centre shafts, loose fixing bolts, under- lubrication, etc.?

  • - Shafts, keys and couplings free of play (loose bolts, etc.)?

  • - Irregular noise in gearboxes, speed reducers , etc.?

  • - Gearboxes, speed reducers, etc. properly lubricated? Any overheating?

5. Provisional Autonomous Maintenance standards

  • - Provisional checking standards completed?

  • - Improvements made to reduce number of checks required?

  • - Improvements done to make checks easier to carry out?

  • - Suitable checking methods and checking intervals adopted?

  • - Ways found to ensure that all checks are done reliably, without any being omitted?

Step 4- 4: General Inspection (Hydraulics and Pneumatics)

  • Pass levels :Score = total score for Review Items 1- 6

    Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

  • Result

    • Pass
    • Fail

Sustainment

  • Steps 1 to 3 activities properly managed and sustained?)<br>- Action against contamination sources being properly sustained?<br>- Good improvements making hard- toaccess areas more accessible?<br>- Cleaning and lubrication standards completed and applied rigorously?

1. Skills Training

  • - Leaders and team members actively creating OPLs and compiling them into manuals to upgrade their skills?

  • - General Inspection skills mastered by all team members?

2. General Inspection

  • - Inspection done correctly, covering all items in category trained?

  • - Minor equipment problems identified reliably during inspection process?

  • - Action taken to deal with these problems?

3. Safety

  • - Progress made in identifying and fixing minor equipment problems that compromise safety?

4. Shop- floor review (Hydraulics and Pneumatics, plus water circulation systems)

  • - Pipes and units free of leaks and stains?

  • - All units effectively protected against dust?

  • - Motors and pumps free of irregular noise and vibration, and switchover valves, solenoid valves, etc. free of odd noises, strange smells, etc.?

  • - Correct oil volume and oil temperature in hydraulic units?

  • - FRLs being used correctly (correct oil volume, clean filter, etc.)?

  • - Hoses correctly installed, clean, undamaged and free of vibration?

  • - Pipes run above floor level, and properly supported?

  • - Pipes easy to inspect and service?

  • - Pressure gauges all in order (correct readings, easily- read dials)?

5. Provisional Autonomous Maintenance standards

  • - Provisional checking standards completed?

  • - Improvements made to reduce number of checks required?

  • - Improvements done to make checks easier to carry out?

  • - Suitable checking methods and checking intervals adopted?

  • - Ways found to ensure that all checks are done reliably, without any being omitted?

Step 4- 5: General Inspection (Electrics)

  • Pass levels :Score = total score for Review Items 1- 6

    Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

  • Result

    • Pass
    • Fail

Sustainment

  • Steps 1 to 3 activities properly managed and sustained?)<br>- Action against contamination sources being properly sustained?<br>- Good improvements making hard- toaccess areas more accessible?<br>- Cleaning and lubrication standards completed and applied rigorously?

1. Skills Training

  • - Leaders and team members actively creating OPLs and compiling them into manuals to upgrade their skills?

  • - General Inspection skills mastered by all team members?

2. General Inspection

  • - Inspection done correctly, covering all items in category trained?

  • - Minor equipment problems identified reliably during inspection process?

  • - Action taken to deal with these problems?

3. Safety

  • - Progress made in identifying and fixing minor equipment problems that compromise safety?

4. Shop- floor review (Electrics)

  • - Distribution panels, control panels and operating panels all clearly marked?

  • - Temperature in distribution panels, control panels and operating panels low enough?

  • - Distribution panels, control panels and operating panels all clean (free of water, oil, dirt, etc.?)

  • - Door seals, filters, etc. on distribution panels, control panels and operating panels all clean and undamaged?

  • - No irregularities in wiring or contacts (overheating, damage, unsafe layout)?

  • - Motors free of overheating, strange noises, vibration?

  • - Sensors securely installed in correct positions, and making proper contact?

  • - Sensors all clean (free of water, oil, dirt, etc.)?

  • - Sensors undamaged, with all lead wires correctly installed? Effectively protected against possible damage?

5. Provisional Autonomous Maintenance standards

  • - Provisional checking standards completed?

  • - Improvements made to reduce number of checks required?

  • - Improvements done to make checks easier to carry out?

  • - Suitable checking methods and checking intervals adopted?

  • - Ways found to ensure that all checks are done reliably, without any being omitted?

Step 1: Initial Cleaning (Assembly Shop)

  • Pass levels :Score = total score for ‘equipment’ (Review Items 1-5) + score for ‘people’ (Review Item 6)

    Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

    step 1 2.PNG

  • Result

    • Pass
    • Fail

1. Cleanliness of surrounding area

  • - Floors free of dirt, oil stains, sawdust, waste material, nuts, bolts, etc.?

  • - All unnecessary objects cleared away?

  • - Cleaning tools, work tools, etc. all stored neatly in designated positions?

  • - Floor marking standards observed?

2. Cleanliness of peripheral equipment, assembly tools, etc.

  • - Free of dirt, dust and oil stains?

  • - All parts suitably tightened and free of wear?

  • - Electric cables undamaged?

  • - Equipment and tools kept in good condition and stored in a well- organised manner?

3. Cleanliness of trolleys, carts, shelving, work benches and other items on which parts are placed

  • - Trolleys, carts, shelves, work benches, etc. positioned correctly?

  • - Unnecessary objects cleared away?

  • - Trolleys, carts, shelves, work benches, etc. stable and in good condition, posing no safety - risks?

4. Cleanliness of storage points for assembly components

  • - Components stored neatly, in parallel and at right- angles (on shelving, pallets, trolleys, etc.)?

  • - Components clearly labelled to show at a glance what each is used for?

5. Contamination sources and hard- to- access areas

  • - Systematic feedback of suggestions to improve precision in upstream processes? - Chart drawn up plotting all sources of dirt and dust, and areas that are hard to clean? Plan formulated for dealing with these?

  • - Improved cleaning tools introduced? - Cleaning areas clearly defined and allocated?

6. Way in which TPM is being addressed

  • - Do all team members have a good understanding of what TPM means, and are they all fully involved in implementing it?

Step 2: Contamination Sources and Hard- to- Access Areas (Assembly Shop)

  • Pass levels :Score = total score for Review Items 1- 6

    Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

    step 2 2.PNG

  • Result

    • Pass
    • Fail

1. Sustainment of Step 1

  • - Cleaning levels achieved in Step 1 (Initial Cleaning) being properly sustained?

2. Measures for achieving appropriate levels of permanent stock

  • - Measures taken to ensure suitable stock levels are maintained?

  • - Improvements and modifications introduced to make remaining stock levels visible at a glance?

3. Countermeasures for peripheral equipment and assembly tools

  • - Sources of dirt, dust, oil leaks, air leaks, etc. all plotted on a chart, and action taken to rectify them?

  • - Improvements and modifications introduced to make remaining stock levels visible at a glance?

4. Countermeasures for component shelves and assembly storage points

  • - Chart drawn up plotting all sources of disruption to storage system, and appropriate action taken?

  • - Improvements and modifications introduced to make remaining stock levels visible at a glance?

5. Improvement and sustainment, and future plans

  • - Systematic feedback of suggestions to improve precision in upstream processes? Strategies worked out for sustaining conditions in the future?

6. Status of activities

  • - All team members actively involved?

  • - Plenty of original thought going into the improvements?

Step 3: Sustainment Standards (Assembly Shop)

  • Self: 90 or over
    Area M.: 85 or over
    Senior M.: 80 or over

  • Result

    • Pass
    • Fail

1. Sustainment of Steps 1 and 2

  • - Cleaning levels achieved in Step 1 (Initial Cleaning) and improvements made in Step 2 (Contamination Sources and Hard- toAccess Areas) being properly sustained?

2. Efficient system based on work standards, checking standards and workplace management standards

  • - Precise standards created for managing assembly equipment, tools, and consumables?

  • - Cleaning and inspection standards created for equipment, tools, assembly areas and storage areas? Standards being observed?

  • - Inspection efficiency maximised; system allows problems or defects to be rectified quickly?

  • - Standards for component storage and placement clearly defined, and visual controls used?

  • - Work standards established and observed?

  • - Layout revised and improved to raise efficiency of assembly work?

  • - Assembly work schedule drawn up by team itself, displayed clearly, and properly maintained?

3. Status of activities

  • - Activity boards used effectively?

  • - Many improvement suggestions being made, and efficiency drive being actively implemented?

4. Improvement and sustainment, and future plans

  • - Improvements being actively pursued? Team discussing how to proceed to next step?

  • - Improvements actively pursued to make checking easier and enhance visual management?

Application for Autonomous Maintenance Review

  • Step No.

  • Review No.

  • Date

  • TPM Office

  • Area Manager

  • Supervisor

  • Originator

Team making application

  • Area / Line/ Team

  • Team Name

  • Leader’s Name

  • No. of members

  • Equipment to be Reviewed

Overall Status of Activities

  • Date last step passed

  • Preferred date for review of current step

  • Number of improvement suggestions

Status of Activities Relating to Current Step

Work Time

  • Total time (hr)

  • Total no. of people

Meeting time

  • Total no. of meetings

  • Total duration (hr)

  • Total no. of participants

Requested focus of review

  • Scope

  • Key points

  • Difficulties overcome

  • Other

Reviewer

  • Reviewer's Name and Signature

  • Duration of review

Conclusion

  • Date

  • Chief Reviewer’s Comments

  • TPM Office’s Comments

Autonomous Maintenance Activities Report

  • Date

  • TPM Office

  • Area Manager

  • Supervisor

  • Originator

  • Step No.

  • Area / Line/ Team

  • Team Name

  • Leader’s Name

  • No. of members

  • Topic

  • - Meetings held
    - Action taken
    - Training received
    - Results achieved

    Meetings = M
    Action = A
    Teaching = T
    Practice = P

  • Tap on '+' to add new Maintenance Log

    • Maintenance Log

  • Date

  • Category

  • Details

  • Participants (note time spent by each person)

  • Time spent

  • No. of people

  • Total Time

  • No. of problems Total time identified

  • No. taken on by team

  • No. taken on by other departments

  • Completed in current month

  • Carried over to next month

Results

Meetings

  • No.

  • No. of People

  • Total time

Action

  • No.

  • No. of People

  • Total time

Teaching

  • No.

  • No. of People

  • Total time

Practice

  • No.

  • No. of People

  • Total time

  • Schedule of Activities for Next Month

  • Focused Improvement Progress Check

    • 1 Identify Situation
    • 2 Select topics
    • 3 Set targets
    • 4 Plan activities
    • 5 Analyse situation
    • 6 Stratify, analyse, and track down causes
    • 7 Take corrective action
    • 8 Confirm and consolidate
    • 9 Assess results and benefits
    • 10 Review

  • Manager's views and advice (comments from review, etc.)

TPM Minutes of Meeting/Action Items

  • Team

  • TPM Office

  • Area Manager

  • Supervisor

  • Team Leader

  • Date (of Issue)

  • Step No.

  • Area / Line/ Team

  • Team Name

  • Leader’s Name

  • Recorder

  • Topic or agenda

  • Participants

  • Absentees

Details of Activities

  • Meeting Date & Time:

  • Action Date & Time

  • Teaching Date & Time

  • Training Date & Time

  • Practice Date & Time

  • Total time(hr.) x (people)=person- hrs.

  • Next topic or agenda

  • Next scheduled meeting; Date and Time

  • Place

  • Supervisor’s comments

  • Area Manager’s comments

  • TPM Office’s comments

Sign Off

  • Report Completed By (Name and Signature)

Autonomous Maintenance (AM) Checklist
SafetyCulture Staff

Autonomous Maintenance (AM) Checklist

Use this Template
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