Autonomous Maintenance in TPM: Jishu Hozen A Complete Guide

TPM Pillar: Autonomous Maintenance in TPM (Jishu Hozen)

What is Autonomous Maintenance?

Autonomous Maintenance is the first and foundational pillar of Total Productive Maintenance (TPM). Also known as Jishu Hozen, it shifts the responsibility of routine maintenance tasks—such as cleaning, inspection, lubrication, and tightening—from maintenance teams to machine operators.

This proactive approach builds ownership and accountability, enabling operators to detect problems early and prevent breakdowns, ultimately improving overall equipment effectiveness (OEE).

8 Pillars of TPM:

1. Autonomous Maintenance – Operators take care of routine maintenance. – Read More

2. Planned Maintenance – Scheduled maintenance to prevent breakdowns. – Read More

3. Quality Maintenance – Eliminate defects at the source. – Read More

4. Focused Improvement – Small teams improve efficiency. – Read More

5. Early Equipment Management – Design equipment for easy use and maintenance. – Read More

6. Training & Education – Skill development for all staff. – Read More

7. Safety, Health & Environment – Ensure a safe, clean workplace. – Read More

8. Office TPM – Apply TPM in admin and support areas. – Read More

Objectives of Autonomous Maintenance

• Empower operators to maintain their equipment
• Detect early signs of malfunction or wear
• Prevent deterioration through regular care
• Reduce machine downtime and improve reliability
• Build cross-functional collaboration and responsibility

The 7 Steps of Autonomous Maintenance

1. Initial Cleaning

Operators clean equipment thoroughly, revealing potential defects or deterioration such as leaks, loose bolts, or hidden debris.

2. Elimination of Contamination Sources

Identify and remove causes of contamination. Modify machines with covers or guards to reduce future dirt accumulation.

3. Establish Cleaning and Lubrication Standards

Develop schedules and guidelines to ensure consistent cleaning and lubrication activities.

4. General Inspection Training

Train operators to inspect components, detect unusual conditions, and recognize early signs of failure.

5. Autonomous Inspections

Operators carry out inspections independently, using checklists and visual cues for reliability.

6. Standardization

Document maintenance tasks, inspection intervals, and criteria for abnormalities in SOPs.

7. Sustaining and Continuous Improvement

Encourage small improvements and feedback from operators to sustain equipment health and refine procedures.

Benefits of Implementing Autonomous Maintenance

• Fewer equipment failures and reduced breakdown frequency
• Improved machine lifespan and performance
• Higher employee engagement and morale
• Enhanced safety and cleanliness in the workplace
• Better coordination between maintenance and operations

Some Common example performed by operator -Autonomous Maintenance TPM

🔧 1. Daily Equipment Cleaning

Operators wipe down machines at the start or end of their shift to remove dust, oil, and debris, helping prevent buildup that could cause malfunctions.

Example:
A lathe operator uses lint-free cloth and approved solvent to clean sliding surfaces daily.

🔍 2. Visual Inspection

Operators check for abnormalities such as oil leaks, unusual noise, loose wires, or worn belts during regular production or after cleaning.

Example:
A packaging machine operator notices a belt beginning to fray and reports it for replacement before it fails.

🛠️ 3. Lubrication

Operators follow a scheduled routine to lubricate moving parts using the correct grade of lubricant, ensuring smooth machine operation.

Example:
An injection molding operator lubricates guide rods every 48 hours using manufacturer-recommended grease.

📋 4. Tightening and Minor Adjustments

Operators use tools to tighten loose bolts or make basic adjustments according to standard procedures.

Example:
A press machine operator tightens guard bolts that were vibrating loose during production.

✅ 5. Use of Checklists

Operators follow inspection checklists that include daily, weekly, or shift-wise checks on key machine parts.

Example:
A CNC machine operator uses a laminated checklist to inspect 10 items before startup, including coolant level and air pressure.

🧠 6. Early Fault Reporting

Operators immediately report any abnormalities or irregular behavior in machines to the maintenance team for prompt action.

Example:
An operator hears an unusual clicking sound during operation and fills out a defect tag for the maintenance team.

Interview Questions & Answers

✅ 1. What is Autonomous Maintenance in TPM?

Answer:
Autonomous Maintenance (also known as Jishu Hozen) is a key pillar of Total Productive Maintenance (TPM) where machine operators are trained and empowered to take responsibility for basic maintenance activities like cleaning, lubricating, inspecting, and tightening. The goal is to detect and prevent abnormalities early, reduce breakdowns, and improve equipment reliability.

✅ 2. Why is Autonomous Maintenance important in the automotive industry?

Answer:
In the automotive industry, high production volumes and precision are critical. Autonomous Maintenance helps operators detect potential issues before they become serious failures, ensuring consistent product quality, minimizing downtime, and supporting lean manufacturing goals. It also fosters operator ownership and collaboration with maintenance teams.

✅ 3. What are the 7 steps of Autonomous Maintenance?

Answer:

1. Initial cleaning

2. Eliminate contamination sources

3. Establish cleaning and lubrication standards

4. General inspection training

5. Autonomous inspections

6. Standardization

7. Continuous improvement and sustaining activities

Each step builds operator skill and gradually transitions responsibility for equipment care from maintenance to production teams.

✅ 4. How does Autonomous Maintenance differ from Planned Maintenance?

Answer:
Autonomous Maintenance involves operators handling basic maintenance tasks regularly, while Planned Maintenance is managed by the maintenance department and includes scheduled repairs, overhauls, and component replacements. Both pillars work together to maintain equipment health but involve different roles and responsibilities.

✅ 5. Can you give an example of an Autonomous Maintenance activity you’ve performed?

Answer:
Yes. At my previous company, I was responsible for a robotic welding cell. I conducted daily visual inspections for leaks, cleaned sensors, and lubricated guide rails using a standardized checklist. This helped reduce weld defects and improved equipment uptime.

✅ 6. What tools or systems are used to support Autonomous Maintenance?

Answer:

• Checklists & Inspection Sheets

• Tagging Systems (Red/Green Tags)

• Andon Signals

• Visual Controls & SOPs

• TPM Boards for tracking issues and progress

These tools standardize activities and help track progress in building operator maintenance skills.

✅ 7. What challenges have you faced with Autonomous Maintenance, and how did you overcome them?

Answer:
One challenge was operator resistance to taking on maintenance tasks. We addressed this through training sessions, explaining the benefits, and involving operators in setting up checklists. Gradually, ownership increased, and breakdowns were reduced.

✅ 8. How does Autonomous Maintenance contribute to OEE improvement?

Answer:
By enabling early detection of issues and regular upkeep by operators, Autonomous Maintenance reduces unplanned downtime (Availability), avoids quality defects (Quality), and supports smoother operations (Performance). This directly contributes to higher Overall Equipment Effectiveness (OEE).

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Conclusion

Autonomous Maintenance sets the stage for sustainable manufacturing performance by integrating maintenance into daily operations. It enhances operator awareness, promotes early fault detection, and is crucial for building a proactive maintenance culture.

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