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Autonomous maintenance 90-day model area plan
An autonomous maintenance model area plan takes one machine, the model area, through the first steps of autonomous maintenance with its own operators before the method spreads to other machines. The team proves on that machine that operators can keep it in its basic condition: step 0 preparation, step 1 initial cleaning and inspection, step 2 sources of contamination and hard-to-access areas, and step 3 provisional cleaning, inspection and lubrication standards. This template has the 13-week plan as a Gantt chart in three phases, with the owner, deliverable and done-when for each activity, a scoring table to choose the model machine from loss data, the team, a KPI board, the day-90 gate, and the expansion plan for months 4 to 12 in three waves, with a worked example.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
When to use it
When to use an autonomous maintenance 90-day plan
- When a plant starts autonomous maintenance and wants to prove it on one machine before asking every team to do it.
- When autonomous maintenance was started everywhere at once and stalled, and the plant wants to restart it properly in one place.
- When a new line or a new machine type comes in and its operators need to learn it from the first week.
- When leaders want a plan they can review every week: who does what, by when, and what done looks like.
How to fill it in
- 1
Choose the model machine from loss data
Score up to three candidate machines (five in Excel) on loss data, visibility, team willingness and repeatability, from 1 to 3. Pick the highest total; on a tie, the higher loss data score wins. Avoid the easiest machine: results there do not convince anyone.
- 2
Name the team and write day 1
Sponsor, pillar lead, the area supervisor and operators, a maintenance technician and the planner. In Excel, day 1 and the status date set the dates of every week and the status of every activity.
- 3
Set the baseline and the day-90 targets
Measure breakdowns, minor stops, tags, cleaning time and how well the standard is followed before the first cleaning. Write a target for day 90 next to each baseline.
- 4
Run the 13 weeks and update the plan every week
Move a bar if your machine needs it, write the week each activity really finished, and add one actual per KPI each week. Late activities turn red in the Excel version.
- 5
Pass the day-90 gate
The sponsor and pillar lead check the six gate items with evidence. If one is not met, fix it before any other machine starts.
- 6
Plan the expansion waves
Wave 1 goes to the machines most like the model machine, with a model area operator coaching each one. Each new machine runs its own 13 weeks against its own baseline and passes the wave gate before the next wave starts.
The 90-day plan
Week by week: autonomous maintenance steps 0 to 3
The standard plan printed on page 1 and in the Excel version. Days 1 to 30 are weeks 1 to 4, days 31 to 60 weeks 5 to 9 and days 61 to 90 weeks 10 to 13. Move the weeks to fit your machine.
| Weeks | Activity | Owner | Deliverable | Done when |
|---|---|---|---|---|
| 1 | Choose the model machine and form the team (Step 0) | Pillar lead | Team list; machine chosen with the selection table | Team named, sponsor agreed, first meeting held |
| 1 to 2 | Measure the baseline (Step 0) | Area supervisor | Breakdowns, minor stops, OEE and cleaning time; photos of the machine | Every KPI on the board has a baseline |
| 2 | Train the team: machine basics, tags and lockout (Step 0) | Maintenance technician | One point lessons on the main units, the tag types and the lockout points | Each operator can name the units and use the tags |
| 3 to 4 | Initial cleaning: clean to inspect, tag every abnormality (Step 1) | Model area team | Tag log with photos | Machine cleaned inside safe covers, every abnormality tagged |
| 4 to 9 | Close the tags (Step 1) | Maintenance planner | Tag log with an owner and a date on each tag | Every tag closed, or planned with an owner and a date |
| 5 to 7 | Find and fix sources of contamination (Step 2) | Model area team | Sources (leaks, spills, chips, dust) with a countermeasure each | Each source has a countermeasure fitted or scheduled |
| 6 to 8 | Improve hard-to-access areas (Step 2) | Maintenance technician | Before and after photos of the new access points | Cleaning and inspection time measured again and lower than the baseline |
| 7 to 9 | Add visual controls (Step 2) | Model area team | Gauge ranges, match marks, flow arrows, lubrication point labels | Each check point can be read at a glance |
| 9 to 11 | Write the provisional cleaning, inspection and lubrication standard (Step 3) | Model area team | Standard with point, method, tool, time and frequency, and a check sheet | The standard fits the time the shift has for it |
| 10 to 12 | Run the standard every shift and adjust it (Step 3) | Area supervisor | Filled-in check sheets and changes to the standard | Operators follow it without help for two weeks in a row |
| 12 to 13 | Step audit for steps 1 to 3 (Audit) | Pillar lead | Autonomous maintenance step audit result | Steps 1 to 3 pass the audit |
| 13 | Day-90 review and decision to expand (Gate) | Sponsor | Day-90 gate sheet, KPIs against baseline, lessons | Gate signed by the sponsor and the pillar lead |
1
- Activity
- Choose the model machine and form the team (Step 0)
- Owner
- Pillar lead
- Deliverable
- Team list; machine chosen with the selection table
- Done when
- Team named, sponsor agreed, first meeting held
1 to 2
- Activity
- Measure the baseline (Step 0)
- Owner
- Area supervisor
- Deliverable
- Breakdowns, minor stops, OEE and cleaning time; photos of the machine
- Done when
- Every KPI on the board has a baseline
2
- Activity
- Train the team: machine basics, tags and lockout (Step 0)
- Owner
- Maintenance technician
- Deliverable
- One point lessons on the main units, the tag types and the lockout points
- Done when
- Each operator can name the units and use the tags
3 to 4
- Activity
- Initial cleaning: clean to inspect, tag every abnormality (Step 1)
- Owner
- Model area team
- Deliverable
- Tag log with photos
- Done when
- Machine cleaned inside safe covers, every abnormality tagged
4 to 9
- Activity
- Close the tags (Step 1)
- Owner
- Maintenance planner
- Deliverable
- Tag log with an owner and a date on each tag
- Done when
- Every tag closed, or planned with an owner and a date
5 to 7
- Activity
- Find and fix sources of contamination (Step 2)
- Owner
- Model area team
- Deliverable
- Sources (leaks, spills, chips, dust) with a countermeasure each
- Done when
- Each source has a countermeasure fitted or scheduled
6 to 8
- Activity
- Improve hard-to-access areas (Step 2)
- Owner
- Maintenance technician
- Deliverable
- Before and after photos of the new access points
- Done when
- Cleaning and inspection time measured again and lower than the baseline
7 to 9
- Activity
- Add visual controls (Step 2)
- Owner
- Model area team
- Deliverable
- Gauge ranges, match marks, flow arrows, lubrication point labels
- Done when
- Each check point can be read at a glance
9 to 11
- Activity
- Write the provisional cleaning, inspection and lubrication standard (Step 3)
- Owner
- Model area team
- Deliverable
- Standard with point, method, tool, time and frequency, and a check sheet
- Done when
- The standard fits the time the shift has for it
10 to 12
- Activity
- Run the standard every shift and adjust it (Step 3)
- Owner
- Area supervisor
- Deliverable
- Filled-in check sheets and changes to the standard
- Done when
- Operators follow it without help for two weeks in a row
12 to 13
- Activity
- Step audit for steps 1 to 3 (Audit)
- Owner
- Pillar lead
- Deliverable
- Autonomous maintenance step audit result
- Done when
- Steps 1 to 3 pass the audit
13
- Activity
- Day-90 review and decision to expand (Gate)
- Owner
- Sponsor
- Deliverable
- Day-90 gate sheet, KPIs against baseline, lessons
- Done when
- Gate signed by the sponsor and the pillar lead
What's on the gates
The day-90 gate and the wave gate for autonomous maintenance
The day-90 gate decides whether the model area is ready to be copied; the wave gate is checked for each new area before the next wave starts. Both are on page 3 of the PDF and on the Excel version's Day-90 gate and Expansion sheets.
Day-90 gate
All met before the first expansion wave starts
- 1Steps 1 to 3 passed the autonomous maintenance step audit
- 2Every tag from the initial cleaning is closed, or planned with an owner and a date
- 3The provisional standard is posted at the machine and followed every shift
- 4Cleaning, inspection and lubrication time is lower than at the baseline
- 5The KPI board has 13 weeks of data against the baseline
- 6The standard, one point lessons and lessons learned are written up so another team can copy them
Wave gate
For each new area, before the next wave starts
- 7The area passed the same day-90 gate as the model area
- 8Its KPIs are measured against its own baseline, not the model area's
- 9The cleaning, inspection and lubrication standard was copied and adapted to the machine, and the copy is recorded
- 10Coaches for the next wave are named and have run a session with the pillar lead watching
- 11The model area was audited again and still holds its standard
A filled-in example
Illustrative, not a benchmarkAn example: a food packaging plant (illustrative, with made-up numbers; the same as page 4 of the PDF and the Excel example sheets). Not a benchmark.
- Model machine choice, loss data, visibility, team willingness and repeatability scored 1 to 3: Filler 3 scored 12, Case packer 1 scored 9 and the Palletizer scored 6. Filler 3 had the most breakdowns and minor stops on the line, and three more fillers of the same model run on the other lines.
- Breakdowns on the model machine: baseline 5 a week, day-90 target 2, week 13 actual 2, so 100% of the gap closed.
- Minor stops: baseline 40 a week, target 15, week 13 actual 18, 88% of the gap closed.
- Tags closed: baseline 0%, target 90%, week 13 actual 88%, 98% of the gap closed.
- Cleaning, inspection and lubrication time: baseline 45 minutes a shift, target 25, week 13 actual 28, 85% of the gap closed.
- Standard followed: baseline 0%, target 95%, week 13 actual 94%, 99% of the gap closed.
The team passed the day-90 gate in week 13. Wave 1 (months 4 to 6) went to Fillers 1, 2 and 4, wave 2 (months 7 to 9) to Case packers 1 and 2, and wave 3 (months 10 to 12) to the Palletizer and the compressor room, with a model area operator coaching each wave 1 filler.
Common mistakes
Choosing the easiest machine
A machine that already runs well proves nothing to the rest of the plant. Pick one with real losses that operators and leaders see every day.
Cleaning without tagging
Initial cleaning is inspection. If the team cleans but does not tag what it finds, the machine looks better for a week and nothing is fixed.
Leaving maintenance tags open
Operators stop tagging when their tags sit for weeks. Give every tag an owner and a date, and show the closed count on the board.
Writing the standard before step 2
A cleaning standard written while the leaks and dirty spots are still there sets the time too high. Fix the sources and the access first, then write it.
Spreading before the gate
Starting more machines before the model machine passes its gate copies an unproven routine. Hold the gate, then expand in waves.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
LeanSuite runs autonomous maintenance with visual CILR checklists, abnormality tags routed to maintenance, and the LMS and Skills Matrix to certify operators on each task.
In the lean glossary
Guides
- Model area: a 90-day plan for each pillar, then expansion
- 7 Steps of Autonomous Maintenance: The TPM Pillar Explained
- TPM Launch: Year One Deployment Guide
- Autonomous Maintenance: Empowering Operators for Equipment Excellence
- The 8 Pillars of TPM Explained
- Yokoten: Horizontal Deployment of Kaizen Best Practices
Put it on the wall
FAQ
Autonomous maintenance 90-day model area plan: common questions
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- EPEI and batch size calculatorHow often each part can come round on a shared machine (EPEI) and how big each batch must be, from demand, cycle times and changeovers, now and after SMED.
- People, process, technology (PPT) assessmentCheck one change before go-live: 18 people, process and technology statements scored 1 to 4 by the people who will use it, the lowest element and the actions.
- Process capacity sheet templateEach machine in a part's routing with manual, auto and tool change time, its capacity per shift, and the step that limits the cell against demand.
- Jidoka worksheet (stop at abnormality)For one line or cell, every abnormality that should stop the work: how it is detected, how the work stops, who is called, the immediate fix and the root cause step, plus a log of real stops.
- Team charter templateA one-page charter for a standing team: purpose, scope, roles, the KPIs it owns, which decisions it makes itself, norms and cadence.
- Chaku-chaku line plannerPlan a load-load cell: time each machine, load and walk, check that every machine is ready when the operator comes back, compare the cell cycle with takt and size the crew.
- Standard operating procedure (SOP) templateA full SOP in the hierarchical step format, from purpose and scope to the steps, records, revision history and approvals, with review checks and an SOP register.
- Process improvement method selectorEight questions about one problem, an example rule that suggests a method and a matrix of nine methods: when each fits, the usual team and time, and the template to start with.
- X-bar and R control chart template25 subgroups with means and ranges, control limits from A2, D3 and D4, signal flags, both charts and a reaction log.
- Gage R&R study sheet10 parts, 2 or 3 appraisers, 2 or 3 trials: EV, AV, GRR, PV, %GRR and ndc by the average and range method.
- Root cause analysis templateOne report from problem statement to proof: containment, evidence, analysis, verified causes, actions and the effectiveness check.
- Safety pillar 90-day model area planThirteen weeks from the incident pyramid to safety standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Quality control pillar 90-day model area planThirteen weeks from the QA matrix to the QM matrix on one model area, a KPI board, the day-90 gate and expansion waves.
- Professional maintenance (PM) 90-day model area planThirteen weeks from breakdown analysis to a running PM calendar on one model machine, a KPI board, the day-90 gate and expansion waves.
- Environment and energy pillar 90-day model area planThirteen weeks from waste and energy maps to area standards on one model area, a KPI board, the day-90 gate and expansion waves.
- Focused improvement 90-day model area planThirteen weeks from the loss Pareto to standardized fixes on one model line, a KPI board, the day-90 gate and expansion waves.
- Logistics and customer service pillar 90-day model area planThirteen weeks from the current-state map to pull on one model value stream, a KPI board, the day-90 gate and expansion waves.
- People development pillar 90-day model area planThirteen weeks from the skills matrix to trained cover on critical tasks in one model area, a KPI board, the day-90 gate and expansion waves.
- Early equipment management 90-day model area planThirteen weeks from lessons on current machines to a tracked start-up on one model equipment project, a KPI board, the day-90 gate and expansion waves.
- Cost deployment pillar 90-day model area planThirteen weeks from the loss map to costed, ranked projects in one model area, a KPI board, the day-90 gate and expansion waves.
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.