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Audit template in the LeanSuite app

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Autonomous maintenance step audit checklist

Audit an area against the Autonomous Maintenance steps before it moves to the next step.

Use this template in LeanSuitePrintable version (PDF)

The full question list

The 28 questions in the audit

Every question is answered Yes, No or N/A. Each No is flagged and asks for a photo and a comment, so the finding arrives with its evidence.

Step 1: Initial cleaning and inspection: Cleaning is inspection

  1. 1The machine has been cleaned thoroughly, inside guards and covers where it is safe to open them
  2. 2Every abnormality found during cleaning was tagged, and the tags are logged
  3. 3Tags from the cleaning are closed, or have an owner and a date
  4. 4Operators can name the main units of the machine and what each one does

Step 2: Sources of contamination and hard-to-reach areas: Stop the dirt, make access easy

  1. 5Sources of contamination (leaks, spills, chips, dust) are listed, each with a countermeasure
  2. 6Points that are hard to clean, inspect or lubricate are listed and improved
  3. 7Cleaning time has been measured and has come down since step 1
  4. 8Before and after photos show the improvements

Step 3: Cleaning, inspection and lubrication standards: Tentative standards

  1. 9A written standard lists each point, the method, tool, time and frequency
  2. 10Lubrication points are marked with the lubricant and the amount or level
  3. 11The standard fits in the time the operators have for it
  4. 12Operators follow the standard without help, and the check sheet is filled in

Step 4: General inspection: Operators learn the machine's systems

  1. 13Operators are trained on the machine's systems (lubrication, hydraulics, pneumatics, electrics, drives, fasteners)
  2. 14Inspection points from that training are added to the standard
  3. 15Visual controls are in place: gauge ranges, match marks, flow directions, labels
  4. 16Abnormalities found by operators are logged and fixed, some by the operators themselves

Step 5: Autonomous inspection: One routine, operator and maintenance tasks split

  1. 17The cleaning, inspection and lubrication standards are merged into one routine and trimmed
  2. 18Operator and maintenance tasks are split clearly, with no gaps and no overlaps
  3. 19Operators run the routine in the planned time
  4. 20Breakdowns and minor stops on the machine are tracked and reviewed with maintenance

Step 6: Standardization: Beyond machine care

  1. 21Tools, spares and materials around the machine have a marked place
  2. 22Standards cover changeovers, quality checks and data recording, not only machine care
  3. 23Operators update the standards themselves when they find a better way
  4. 24The area passes its 5S audit

Step 7: Autonomous management: The team runs and improves its own standards

  1. 25The team sets and tracks its own goals for the machine (breakdowns, quality, OEE)
  2. 26The team starts improvement work without being asked
  3. 27Results hold between audits
  4. 28Operators coach new team members on the standards

When to use it

  • When it is due on your audit programme, or after a change or a problem.
  • An auditor or leader answers each question from what they see, hear and read in the area.

How it is scored

The template is built with points per answer and a pass mark of 80. In this library every audit is set to pass at 80 and every inspection at 90. Each submitted audit shows its score and pass or fail, and every No is flagged with its photo and comment.

Change the points or the pass mark after you clone it. How rules and scoring work.

Read and print

More in maintenance and equipment

All maintenance and equipment templates

Use this template in LeanSuite

It is ready in the Template Marketplace inside Lean Creator as “Autonomous Maintenance Step Audit”. Clone it into your plant, change any question, then schedule it to a person, role or asset with reminders. Auditors complete it on a phone or tablet, with photo evidence where required.

Not on LeanSuite yet? On a 90-day pilot our team sets up your account and digitizes the forms and checklists you use today, this one included.

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