Page 89 - TPM A Route to World-Class Performance

70 TPM-A Route to World-Class Performance

To make it easy to do
Objective
things right
... and difficult to

Figure 4.6 Improvements

right way of doing things by clear visual aids. This is error-proofing: to make
it easy to do things right and difficult to do things wrong (Figure 4.6). Some
examples of visual marking to encourage ease of inspection, discipline, order
and tidiness are as follows:

0 Where sight glasses are used, make sure that they are clean and that the
high and low points are boldly marked and colour coded so that they
can be seen at a glance.
0 Mark gauges green for 'go' and red for 'no go'.
0 Use small windmills to indicate extraction fans and motors working.
0 Indicate the correct level on oil bottles as a maximum and a minimum.
An elastic band on the bottle will show the level at the previous check,
to give the rate of use.
0 Use line indicators on bolts and nuts to show position relative to their
fixture base.
Provide inspection windows for critical moving parts.
0 Colour tag clearly those valves which are open and those which are
closed.
0 Highlight critical areas which must be kept scrupulously clean.
0 Identify covers which are removable by colour coding them.
0 When there is an agreed inspection routine, number in sequence those
points which require attention.
0 Prepare quality colour photographs of equipment standards and ensure
that these are readily accessible to operators.
0 Make up shadow boards for tools and spares so that the correct location
of every item is immediately apparent.
0 Indicate the correct operation of machines by instructions and labels
which are visible on the machine, kept clean and accessible.
0 Display charts and graphs adjacent to the equipment to show standards
and to indicate progress towards objectives.

Having completed the first two steps towards autonomous maintenance,
operators will have learned to detect problems and to understand the principles
and procedures of equipment improvement. They can now take the next
steps.

Step 3 Cleaning and lubrication standards
Much will have been learned from the initial cleaning, orderliness and discipline