Lean and CI poster
Updated · Free to print and share
Autonomous maintenance 7 steps poster
Autonomous maintenance (jishu hozen) is the TPM pillar where operators take care of the basic upkeep of their own equipment: cleaning, inspecting, lubricating and tightening. It is built up in seven steps, each ending with an audit: initial cleaning, sources of contamination, provisional standards, general inspection, autonomous inspection, standardization and autonomous management. This poster shows the seven steps with a line on each.
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The words on the poster
Autonomous maintenance: 7 steps
Operators take care of their own equipment, with maintenance alongside.
- Initial cleaning Clean thoroughly, inspect as you go, tag every problem.
- Sources of contamination Stop dirt at the source. Make hard spots easy to reach.
- Provisional standards Write the clean, inspect and lubricate routine.
- General inspection Learn how each system works and what normal is.
- Autonomous inspection Operators run the full inspection themselves.
- Standardization Extend standards to the whole area.
- Autonomous management Teams run and improve their own routines.
- Audit at the end of every step. Lock out before reaching into any machine.
On the floor
How to use it
- 1
Put it at the machine or line that is working through the steps, with its current step marked.
- 2
Use it at step audits to show what the next step asks for.
- 3
Teach it with the free 7-step autonomous maintenance training deck.
- 4
Pair it with the free AM step audit and CILR checklist.
Which size to print
- 24 x 36 in or A2: a main wall or team board, read from a few metres away.
- 18 x 24 in or A3: a station or notice board. The A3 file also fits 11 x 17 in paper.
- Letter or A4: a clipboard, binder or handout, on any office printer.
Every PDF is vector, so it stays sharp at full size. Nothing runs to the edge of the page, so no bleed is needed.
Templates, decks and guides to go with it
- Autonomous maintenance training presentation: the 7 stepsFree training deck: The 7 steps of jishu hozen, who does what and how step audits work, in 19 slides with notes and a quiz.
- Autonomous maintenance (CILR) checklist20 clean, inspect, lubricate and retighten checks with a box per day, an abnormality log and sign-off.
- Autonomous maintenance step auditCriteria for each of the seven autonomous maintenance steps, scored 0 to 2, with the step result and the decision to move on.
- TPM tag logEvery abnormality tag with type, who fixes it, priority and dates, with days open and counts by type and week.
- Lubrication schedule templateEvery lube point with lubricant, method, amount, frequency and who, with next due dates and a monthly sign-off record.
- Topic: TPM and maintenanceEvery guide we have on the subject, sorted.
A poster reminds. A routine makes it stick.
See how plants run their audits, improvements and follow-ups in LeanSuite, on a call built around your own problem.
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