Page 90 - TPM A Route to World-Class Performance

Techniques tu deliver the TPM principles 71

procedures, and it will now be possible to set standards for the ongoing care
of plant and machines. This will lead logically towards the next step.

Step 4 General inspection
Helped by other members of the team, operators can be guided towards the
point where they can carry out general inspection themselves. They will then
have reached the stage where they know the function and structure of the
equipment and have acquired the self-confidence to make a much more
significant contribution towards the goal of more reliable machines and better
products.
Step 5 Autonomous inspection
As the term implies, operators can now carry out self-directed inspection
routines and repairs/servicing as required.

Step 6 Organization and tidiness
Initial cleaning and the application of the 5S/CAN DO philosophy will by
now have worked through and started to have major effects. In parallel with
this, operators will have reached the stage where they can take responsibility
for performing autonomous inspection - always within the limits of their
skills, experience and training and always backed, where necessary, by their
maintenance colleagues. They will have developed an understanding of the
relationship between equipment accuracy and product quality. This leads to
the final step.

Step 7 Full autonomous maintenance
At this stage, operators will be equipped to maintain their own equipment.
This will include cleaning, checking, lubricating, attending to fixtures and
precision checking on a daily basis. They are now equipped to apply their
newly developed skills and knowledge to the vital task of continuous
improvement.
The key point of emphasis in developing these asset care routines is
empowerment. The operators’ and maintainers’ own ideas are encouraged and
adopted on the basis that ’If it is my idea and it is embodied in the way in
which we operate and look after our equipment, then I will stick with it!’ On
the other hand, ’If it is imposed from above, then I might tick a few check
boxes, but I won’t actually do anything!’ The progress from cleaning to full
autonomous maintenance is illustrated in Figure 4.7.
The condition cycle of the TPM improvement plan (Figure 3.19) moves
through the following steps:
0 Criticality assessment
Condition appraisal
Refurbishment programme
0 Future asset care