Basic contents of equipment autonomous inspection management

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The basic elements of autonomous equipment inspection management are: 1. How many steps are there in autonomous maintenance? What are they respectively? The 5 steps of self-preservation in SHE BIE DIAN JAIN ZI ZHU GUAN LI are as follows: initial cleaning, identification of the six sources of problems and formulation of improvement measures, establishment of inspection standards, comprehensive inspection training, and self-management. 2 Definition of initial cleaning: THROUGH daily cleaning and inspections, dust and foreign particles attached to and inside the equipment are completely removed; even the smallest debris and various tiny contamination spots are cleared away. At the same time, minor defects such as aged components due to use, small cracks caused by friction, and loose screws must all be identified one by one. Initial cleaning is the first step in autonomous maintenance; it is primarily aimed at identifying any abnormal issues with the equipment. Its purpose is to train employees (operators) in their ability to carry out tasks on their own and to detect problems, so initial cleaning should not be confused with the regular thorough cleanings carried out by employees. 3 The difference between initial cleaning and cleaning in 6S: SHE BIE DIAN JAIN ZI ZHU GUAN LI. 6S cleaning refers to removing dirt from the workplace in order to keep it clean. Its focus is on surface cleaning, with a relatively simple motivation. Initial cleaning is a continuation of 6S. Firstly, initial cleaning requires not only the cleaning of the surface of the equipment but also a thorough cleaning of its interior. Through initial cleaning, the equipment is brought back to its optimal condition, something that cannot be achieved by the regular 6S cleaning activities. Secondly, in addition to the purpose of cleaning, the motivation for initial cleaning also includes the task of identifying minor defects in the equipment and helping operators become familiar with it. The first thorough interaction between the operator and the equipment takes place through this initial cleaning process, which is something that is not covered by the cleaning aspect of 6S. Therefore, after implementing 6S practices, it is necessary to introduce TPM activities in order to achieve maximum benefits. 4 Initial cleaning tasks: SHE BIE DIAN JAIN ZI ZHU GUAN LI (1) Cleaning of the equipment itself (internal and external areas) ； (2) Detection and restoration of microdefects ； (3) Production of equipment nameplates and labels ； (4) Create a standard manual for the initial cleaning of equipment ； (5) Prepare equipment inspection standard documents ； (6) Oil injection. 5 Key Points for Initial Cleaning SHE BIE DIAN JAIN ZI ZHU GUAN LI (1) Cleaning is essentially inspection ； (2) The operator performs the task manually ； (3) The cleaning of the main equipment’s exterior must also extend to accessories related to the equipment, such as sockets and connecting cables. Ensuring that these components are clean is crucial for maintaining the optimal performance of the main equipment ； (4) The key to cleaning the interior of the equipment is to remove as many detachable components as possible in order to carry out a thorough cleaning and get rid of the dust that has accumulated over the years ； (5) Relevant tools such as wrenches must be brought along when cleaning; any loose screws should be tightened promptly ； (6) Treat cleaning as part of the job; include cleaning results in individual performance evaluations ； (7) Carry out equipment cleaning based on the principle that \"people should brush their teeth and wash their faces every day,\" and overcome the mistaken belief that \"it will get dirty again even if it’s cleaned.\" 6 What are microdefects? SHE BIE DIAN JAIN ZI ZHU GUAN LI So-called micro-defects refer to minor imperfections that are somewhat apparent but not entirely so, and have a minimal impact on the overall outcome. 7 What is OPL and what is its purpose? SHE BIE DIAN JAIN ZI ZHU GUAN LI OPL is the English abbreviation for “One Point Lesson”. Its purpose is to illustrate the key points of inspections through a combination of text and images, thereby establishing standard operating procedures. This ensures that anyone following these procedures will not make any mistakes. Functions: First, it can be used as an intuitive teaching material for comprehensive inspections of on-site equipment; second, it can be printed as a reference guide for inspection procedures and posted on site to serve as a reminder. 8 What are the common types of OPL? What are they respectively? SHE BIE DIAN JAIN ZI ZHU GUAN LI There are five common types of OPL, namely: ① OPL for device operation prompts ； ②Oil injection system diagram OPL ； ③Equipment inspection routes and node indication OPL ； ④Equipment Inspection OPL ； ⑤The device operates under the OPL system. 9 The “six sources” in six-source investigation and types of countermeasures SHE BIE DIAN JAIN ZI ZHU GUAN LI The “six sources” refer to: pollution sources, sources that are difficult to clean, failure sources, waste sources, hazard sources, and defect sources. Types of improvement countermeasures: prevention-type, elimination-type, and collection-type. 10 Requirements regarding the content of the Six Sources dashboard: SHE BIE DIAN JAIN ZI ZHU GUAN LI. (1) The content of the Six Sources dashboard must relate to the current month; comparison photos should be updated at least once per month, and these photos must be taken from the same angle. The improvements made should be clearly visible ； (2) In the first row of the columns for sequence numbers in the monthly discovery table, monthly processing table, and monthly unresolved table, the colors should be yellow, green, and red respectively; the sum of the processed items and the unresolved items must equal the number of discovered items ； (3) “Understanding the six sources” and “Countermeasures for the six sources” must be filled out with appropriate content based on the actual conditions of each respective device ； (4) For Six-Source problems, it is essential to create an improvement project registration form. For issues resolved by the work teams themselves, this form should be kept by the teams. Forms related to issues requiring resolution by the workshop or the company should be retained by the respective equipment management departments of the workshop and the company. These registration forms serve as a basis for inspecting Six-Source problems and must be properly preserved ； (5) The Six Sources board should be hung at the equipment location or in a place within the workshop where there is a high concentration of people and it can be seen easily. 11. Creation of inspection criteria: SHE BIE DIAN JAIN ZI ZHU GUAN LI (1) covers the daily inspection tasks for operators and should not include specialized inspection tasks ； (2) For continuously operating equipment, the daily inspection items should not include those that the operator must check every hour; the daily inspection checklist can be adjusted accordingly based on the frequency of such inspections ； (3) The daily inspection form must be posted on-site, and inspectors should fill it out on-site in accordance with the filling instructions ； (4) The inspection sequence table should be prepared in a format that combines text and illustrations ； (5) Strictly implement three-level inspection ； (6) This form is issued once a month. 12 Definition and Role of Comprehensive Inspection Training SHE BIE DIAN JIAN ZI ZHU GUAN LI Comprehensive inspection training refers to the practice of setting higher standards for equipment operators with regard to the autonomous maintenance of equipment. Through on-site training in inspection techniques, operators learn more in depth about the structure, performance, and operating principles of the equipment, thereby enabling them to carry out more thorough inspections. This approach ensures a full understanding of all aspects of comprehensive inspection, helps to identify potential problems, and allows the equipment to return to its original condition through regular inspection activities. Function: (1) Reduce the failure rate of equipment ； (2) Eliminate micro-defects in the equipment ； (3) Comprehensively improving employees’ ability to carry out self-maintenance 13 Precautions for conducting comprehensive inspection training SHE BIE DIAN JAIN ZI ZHU GUAN LI (1) Professional inspection personnel, in accordance with the inspection guidelines, inspection sequence sheets, and daily inspection forms, provide on-site training to operators ； (2) After completing the training and learning how to conduct inspections, the operators should sign to confirm on the inspection sequence sheet, file it for backup, and use it as a basis for assuming responsibility in the future (15%) ； (3) The operators who receive training are all employees of this position; the professional inspectors responsible for conducting the training should be patient until each operator truly masters the contents and methods of daily inspections. 14 Autonomous Management: SHE BIE DIAN JAIN ZI ZHU GUAN LI. Autonomous management refers to a form of management in which no management is carried out at all; it reduces the interference from managers and allows employees to manage their own work on their own. As autonomous maintenance progresses to the stage of autonomous management, it is necessary to establish an autonomous management system – a system designed to regulate employees, ensuring that they adhere to the operational standards they have set themselves. This represents a summary of the TPM autonomous maintenance activities, and it also enables the scope of TPM to extend beyond equipment-related activities to cover all production processes on site. Therefore, the step of autonomous management begins with eliminating various forms of waste on the shop floor, moving toward the goal of pushing limits. 15 Differences between autonomous equipment maintenance and professional maintenance. Autonomous maintenance refers to the daily upkeep of equipment carried out by the operators in the department that uses it; this includes regular cleaning, lubrication, tightening, and other routine tasks. Operators must adhere to the guidelines for using the equipment and replace or repair any damaged components promptly. Professional maintenance is specialized care for equipment carried out by the equipment management department, including planned regular inspections, periodic upkeep, as well as medium and major repairs. Professional preservation activities are characterized by planning, high professionalism, and a strong level of effort in preservation. If the equipment is compared to a baby, then the mother of the baby is the operator of the equipment; tasks such as feeding the equipment oil, cleaning it, and detecting oil leaks, overheating, and abnormal vibrations fall under the responsibilities of the equipment operator for its own maintenance. Professional maintenance in the equipment management department is akin to a doctor for infants – the doctor’s role is to prevent diseases from occurring and to treat them promptly once they do arise. Therefore, the tasks of professional maintenance involve two aspects: one is to prevent equipment problems through regular inspections and early intervention ； Secondly, it enables timely resolution of issues that arise with the equipment, thereby maximizing its efficiency and ensuring smooth production