Total Productive Maintenance TPM Operator Autonomous Care Checklist
Daily operator-led autonomous maintenance procedure for production equipment — covering LOTO isolation, cleaning, detailed inspection, critical parameter measurement, lubrication, function verification, and documentation escalation.
This procedure defines the standard work sequence for production operators to perform daily autonomous care on their assigned machinery. By systematically cleaning, inspecting, lubricating, and documenting machine condition, the operator becomes the first line of defence against degradation, defect generation, and unplanned downtime. The goal is zero breakdowns, zero defects, and zero safety incidents through operator ownership of basic machine health.
Applies to all production equipment within manufacturing cells designated for TPM Level 1 (Autonomous Maintenance) — including CNC lathes, milling centres, presses, injection moulding machines, conveyors, and robotic workcells. Excludes utility systems (compressors, chillers) and equipment under active corrective maintenance. Operators who have completed the TPM Awareness and LOTO training modules are authorised to perform this checklist. A signed-off daily log is required before production release.
- Zero-energy isolation is mandatory before any cleaning, inspection, or lubrication task that requires entering the machine envelope. Follow plant-specific lockout/tagout procedure — personal padlock, group hasp, and verification of energy isolation.
- Wear ANSI Z87.1-rated safety glasses with side shields, cut-resistant gloves (ANSI A5 or higher), steel-toed boots, and hearing protection if ambient noise exceeds 85 dBA. Remove all jewellery and secure loose clothing.
- Bearing housings, spindle drives, and hydraulic systems may reach surface temperatures exceeding 60 °C. Use the infrared thermometer to verify surface temperature before contact. Allow one minute of cool-down if reading exceeds 50 °C.
- Only use approved degreasers and lubricants with an available Safety Data Sheet (SDS). Do not mix cleaning agents. Wear nitrile gloves when handling solvents. Ensure adequate ventilation in the work area.
- Keep hands clear of all pinch points — ball screw covers, belt tensioners, chain drives, and clamp mechanisms. Use the 3-in-1 inspection gauge to probe seals and drains; never use fingers for blind probing.
- 3-in-1 inspection gauge (feeler, hook, mirror) — part no. INS-100
- Approved industrial degreaser (SDS on file) and lint-free cellulose wipes
- Calibrated grease gun with machine-specific NLGI #2 or #1 grease
- Digital torque wrench (range 5–200 N·m, calibrated within 12 months)
- Tachometer / strobe light for rotational speed verification
- Infrared thermometer (contact or non-contact, ±1.5 °C accuracy)
- Refractometer for coolant concentration check
- Operator autonomous care checklist (paper or digital CMMS form)
- Lockout/tagout kit (personal padlock, group hasp, danger tag, lockout station key)
- PPE as listed in Safety Precautions above