Compilation of TPM management knowledge [Part 3] (Bonus content; be sure to save it!)

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　　Part 3: Key points of the first phase of TPM autonomous maintenance
42. In a general sense, cleaning refers to the act of making something clean by removing dust, dirt, and debris； And the cleaning in TPM activities is essentially inspection, which involves checking to identify minor defects on the equipment. 　　43. What is the definition of initial cleaning? 　　Answer: Focusing on the equipment, carry out initial cleaning, identification of issues, improvement, and restoration activities; help employees develop the mindset that \"I am responsible for maintaining my own equipment,\" emphasize the importance of \"minor defects,\" and fully understand the significance of \"cleaning = inspection.\" 　　44. Purpose of initial cleaning: (1) Human aspect: By carrying out cleaning, employees become familiar with team activities; through practice, they gain a better understanding of the equipment, develop their ability to work independently and identify problems, realize that \"cleaning is a form of inspection,\" and consider how to carry out cleaning in a comfortable, convenient, and efficient manner. 　　(2) Equipment: Thoroughly remove dust contamination to make potential defects more visible, facilitating equipment inspection and the detection of any abnormalities. This also involves restoring and improving any irregularities in the equipment—essentially achieving zero micro-defects. 　　45. Requirements for initial cleaning: ① Clean both visible and invisible areas thoroughly ； 　　② Cleaning work should be managed in a standardized manner; cleaning standards should be established, and cleaning should be carried out in accordance with those standards ； 　　③ With persistent effort, carry out the cleaning work as part of daily routine on a continuous basis. 　　46. What are the two key aspects to focus on in equipment failure management? 　　Answer: One is fault diagnosis, and the other is fault elimination; these are effective measures and methods to reduce downtime. 　　47. The three levels of standardized management for equipment are: pre-management, in-process management, and post-management. 　　48. Time losses related to equipment include: equipment failures, minor shutdowns/idling, speed losses, defects, and rework ； Human-related loss in terms of manpower includes: management losses, operational losses, production line organization losses, maintenance losses, and measurement and adjustment losses. 　　49. TPM’s activities to identify and eliminate the “six sources,” which are pollution sources, waste sources, failure sources, defect sources, accident hazards, and sources of difficulty in cleaning. 　　50. The equipment failure period is divided into three stages: the initial failure stage, the occasional failure stage, and the wear-out failure stage. 　　51. Equipment inspection involves using the five senses—hearing, taste, touch, sight, and smell—to detect any abnormalities in equipment and construction at an early stage, thereby establishing a mechanism for promptly responding to such abnormalities. 　　52. Four steps to eliminate waste: Understand what waste is, identify where waste occurs in the processes, use appropriate tools to eliminate the identified types of waste, and implement continuous improvement measures by repeating these steps. 　　53. Purpose of the basic theory on employee training equipment: to understand the structure, performance, and operating principles of the equipment ； Use reference equipment to understand the device structure and inspection methods on-site. 　　54. MTTR (Mean Time To Repair): MTTR = Total time the equipment is down / Total number of failures. 55. MTBF (Mean Time Between Failures): MTBF = Operating time of the equipment / Number of failures. 56. Classification of equipment degradation: (1) Natural degradation: A reduction in lifespan and deterioration in performance caused by physical and chemical factors such as the equipment’s operation, load, and time. 　　(2) Human-induced degradation: Performance and lifespan reduction caused by improper use, poor maintenance, destructive repairs, or other human factors. 　　(3) To prevent human-induced deterioration and maintain the natural rate of deterioration, it is necessary to eliminate degradation by strengthening maintenance practices such as cleaning, tightening, and lubrication, in order to keep the equipment in its optimal condition. 　　57. Equipment inspections can generally be divided into three types: inspections before startup, inspections during operation, and periodic inspections. 　　(1) Pre-startup inspection: Verify whether the equipment is ready for operation. 　　(2) In-service inspection: Verify that the equipment is operating properly and that its parameters are within normal ranges. 　　(3) Periodic inspection: Regular checks and maintenance of the equipment carried out after it is shut down. 　　58. The 8 key elements for establishing a equipment inspection system are: (1) Designating personnel: Appointing part-time or full-time inspectors who are responsible for equipment operation. 　　(2) Fixation points: Identify the locations of equipment malfunctions, and specify the inspection points, items, and contents. 　　(3) Quantification: Quantitative measurement of the equipment’s tendency toward degradation. 　　(4) Fixed cycle: Different inspection cycles are assigned for different devices and their failure points. 　　(5) Establishing standards: Providing the criteria for determining whether each inspection point is in good condition, that is, the judgment standards. (6) Inspection schedule: The inspection schedule, also known as an operation card, guides inspectors to carry out their tasks along the specified routes. 　　(7) Fixed records: including operation records, anomaly records, fault records, and trend records, all have a fixed format. 　　(8) Process for handling inspection results: Define the procedures for inspection tasks and the processing of inspection results. For issues that require immediate attention, the maintenance staff should be notified; those that are not urgent should be recorded for planned inspection and handling. 　　59. Daily inspections include: cleaning, lubrication, tightening, adjustment, and reporting of potential hazards. 　　60. Classified by whether disassembly is required: disassembly inspection and non-disassembly inspection. 61. The ten key elements of equipment inspection: pressure, temperature, flow rate, leakage, condition of grease/oil supply, noise, vibration, cracks (breakages), wear, and looseness. 　　62. The equipment can be divided into six major systems: ① Pneumatic system ； ②Lubrication system ； ③Hydraulic system ； ④Drive and transmission system ； ⑤Transmission system ； ⑥Electrical control system. It is essential to conduct regular inspections of these six systems to check for any abnormalities, to study their natural degradation cycle, and to carry out repairs or replacements in a timely manner. 　　63. The meaning of “four understandings and three skills” in equipment management （1）Four understandings: It refers to the requirement that equipment operators must know about the equipment they operate: its performance, principles, structure, and purpose. 　　(2) The three skills: refer to the ability of equipment operators to operate the equipment, to maintain it, and to troubleshoot faults. 64. Autonomous maintenance and planned maintenance are two aspects of equipment maintenance, both of which are essential. 　　(1) Autonomous maintenance emphasizes that employees of an enterprise take the initiative to carry out comprehensive management, maintenance, and upkeep of the enterprise on their own ； 　　(2) Planned maintenance refers to the systematic preventive management, maintenance, and upkeep of equipment by a company. Therefore, the entities responsible for implementing them are different. 　　65. The “five fixes” for equipment lubrication refer to: fixed location, fixed quality, fixed quantity, fixed frequency, and fixed person in charge. 　　66. Three key points for equipment lubrication: type of oil ； 2) Amount of oil supplied ； 3) Oil feeding cycle. 　　67. What is the function of lubricating oil? 1. Reduce friction ； 2. Reduce wear ； 3. Cooling effect ； 4. Anti-rust effect 5. Power transmission ； 6. Sealing function ； 7. Shock absorption ； 8. Purifying effect. 　　68.6S refers to sorting, straightening, sweeping, cleaning, discipline, and safety respectively. 　　69.6 Routine inspections at the S point also require procedural and standardized management: identifying the area, personnel, standards, frequency, and methods, as well as having an inspection and evaluation plan. 　　70. The method of taking photographs of the same equipment, at the same location and from the same angle before and after improvement, in order to compare the conditions before and after the improvement, is called fixed-point photography. 　　71. Definition of OPL training: OPL is a course developed by the group members themselves, centered around questions for education, used for exchanging experiences and self-learning, and is an educational method aimed at resolving doubts. The content can be educational communication on a specific topic such as basic knowledge, troubleshooting, experience sharing, or areas for improvement. The time is generally kept to about 5 to 10 minutes, during which one can basically master the relevant content through self-study. 　　72. Purpose of OPL training: To increase knowledge and skills in a short period of time; these knowledge and skills are often needed by employees at any time, and it also helps to enhance their sense of responsibility. 　　73. Types of OPL 　　(1) Basic knowledge: When carrying out production or TPM activities, one should hold the attitude that it is necessary to know certain things, and acquire new knowledge through training and education. 　　(2) Skills and techniques: Share experiences of success or failure for everyone’s reference. 　　(3) Troubleshooting: Use actual malfunctions and defective cases to reflect on any deficiencies in knowledge and skills, thereby preventing their recurrence. 　　(4) Improvement examples: Learn *new improvement thinking methods through horizontally interconnected improvement examples to enhance the quality of improvements in autonomous maintenance activities. 　　74. Key points for compiling OPL single-topic materials: 1) Determine the theme ； 　　2) Have those who have experienced it firsthand write it ； 　　3) It doesn’t take much time; on average, each teaching material can be completed in about 30–60 minutes. The explanation should last around 10 minutes ； 　　4) The goal is to conduct a single-session training session every day, which means that one person should complete a training material on a daily basis ； 　　5) The text in the textbook should be simple and easy to understand, with large font sizes ； 　　6) Make more use of comics, charts, and photos to make it vivid ； 　　7) Easy for trainees to remember ； 　　8) Set aside time every day for the trainer to explain the training to other employees. 　　9) Register the trained teaching materials and display them on a board for everyone’s reference. 　　10) The content that is already familiar to everyone is taken down from the board, compiled into a booklet, assigned registration numbers, and stored uniformly. 　　75. In OPL one-on-one training, the 5W2H principle is: (what) what content to cover, (who) who will deliver the training, (where) the setting for the training, (when) when the training will take place, (why) why it is done this way, (how) how to carry it out, and (how much, how many) the standards for assignments. 　　76. The seven stages of autonomous maintenance are: (1) Stage 0 is 6S ； 　　(2) Phase 1 is the initial cleaning ； 　　(3) Stage 2 is the source of occurrence. Countermeasures for difficult areas ； 　　(4) Phase 3 is cleaning, inspection, and oiling – a provisional standard document ； 　　(5) Stage 4 is the overall inspection ； 　　(6) Stage 5 is autonomous inspection ； 　　(7) Phase 6 is quality maintenance ； 　　(8) Stage 7 is autonomous management ； 　　77. Rust formation on the fixing bolts of equipment is a basic condition among the eight types of unreasonable conditions. 　　78. The loosening of the fixing bolts on the equipment is a minor defect among the eight types of unreasonable conditions. 　　79. Each question raised during the cleaning process should correspond to an OPL. 　　80. The most appropriate training time for an OPL is 5–10 minutes. 　　81. The correct mindset that TPM should foster is that I am responsible for maintaining my equipment. 　　82. The final step in the initial cleanup process is to hold a summary meeting. 　　83. The eight irrationalities refer to organization, arrangement, minor defects, basic conditions (cleaning, lubrication, tightening), difficult-to-access areas, sources of contamination, unsafe areas, and others. 　　84. The definition of sorting out the eight types of unreasonable elements is: Answer: Distinguish between necessary and unnecessary items on the equipment, and handle the unnecessary items ； 　　85. The definition of rectifying the eight types of irrationalities is: Answer: To prevent an excess or shortage of necessary items on the equipment, and to facilitate access to them ； 　　86. The definition of the eight types of minor defects that are considered unreasonable is: Answer: Small flaws that have little impact on the equipment at present but may grow in significance over time ； 　　87. The definition of the eight basic conditions related to unreasonable aspects is: Answer: Basic tasks such as cleaning, tightening, and lubrication of the equipment ； 　　88. The definition of the sources of the eight types of irrationalities is: Answer: The locations where equipment failures, defects, disasters, and pollution occur ； 　　89. The definition of difficult areas with eight types of unreasonable features is: Answer: Parts on the equipment that hinder human movement ； 　　90. The definition of the eight types of unreasonable components across all areas is: Answer: Parts on the equipment that pose a hazard or potential hazard to people ； 　　91. All factors related to equipment that cause failures, quality losses, etc., are what we call defects. Based on their impact on losses, we classify defects into three categories: major defects, medium defects, and minor defects. 　　92. Initial cleaning can remove dust contamination, thereby bringing potential defects to light, restoring degraded or abnormal conditions, making it easier to inspect the equipment, and increasing employees’ familiarity with it. 　　93. Cleaning in the general sense refers to the act of thoroughly cleaning away dust, dirt, and debris ； Cleaning in TPM activities is essentially inspection, using cleaning to identify minor defects on the equipment. 　　94. The methods for identifying unreasonable issues include vision, hearing, touch, smell, and taste. 　　95. What are the sequential steps for carrying out initial cleaning activities? 　　(1) Formation of the initial team ； 　　(2) Step 2: Select the group name and slogan ； 　　(3) Step 3: Determine the organizational structure for group activities ； 　　(4) In the fourth step, team members divide the tasks for cleaning the area ； 　　(5) The fifth step is to determine the equipment preparation before cleaning, that is, to select one piece of equipment ； 　　(6) Step 6: Prepare appropriate cleaning and maintenance tools ； 　　(7) Step 7: Safety education before cleaning ； 　　(8) In the eighth step, the team leader assigns tasks and begins the cleaning ； 　　(9) Record the unreasonable points of the ninth step and take photos ； 　　(10) Summary of the tenth step: improvement measures for the unreasonable aspects and sharing of members’ insights.