Autonomous Maintenance in TPM: Jishu Hozen – A Complete Guide

Autonomous Maintenance, commonly known as Jishu Hozen, is one of the important pillars of Total Productive Maintenance (TPM). It focuses on involving machine operators in the routine care, inspection, cleaning, lubrication, and early identification of equipment abnormalities.

In a traditional maintenance system, operators mainly focus on production while maintenance technicians are responsible for equipment care. Autonomous Maintenance changes this approach by giving operators an active role in maintaining the basic condition of their machines.

The objective is not to turn production operators into maintenance engineers.

Instead, the objective is to ensure that operators can recognize abnormalities early, maintain basic equipment conditions, and prevent small problems from becoming major failures.

For manufacturing professionals working in Production, Quality, Maintenance, Manufacturing Engineering, TPM, Lean Manufacturing, and Continuous Improvement, understanding Jishu Hozen can be extremely useful.

This complete guide explains Autonomous Maintenance, its meaning, objectives, seven steps, implementation process, examples, benefits, common mistakes, and practical applications in manufacturing.

What Is Autonomous Maintenance?

Autonomous Maintenance is a TPM approach in which machine operators take responsibility for basic routine maintenance activities related to the equipment they operate.

The Japanese term Jishu Hozen can broadly be understood as autonomous or self-maintenance.

Typical activities include:

Cleaning
Inspection
Lubrication
Tightening
Abnormality identification
Minor adjustments
Basic equipment care
Maintaining standard conditions

The concept is based on a simple principle:

The person who operates the machine every day is often in the best position to notice changes in its normal condition.

For example, an operator may notice:

An unusual vibration
An abnormal sound
An oil leakage
A loose component
A temperature increase
A damaged hose
A change in product quality
Abnormal machine movement

If these abnormalities are identified early, maintenance personnel can investigate and correct them before they develop into larger failures.

What Is Jishu Hozen?

Jishu Hozen is the Japanese term commonly associated with Autonomous Maintenance.

It means that operators take ownership of the basic condition of their equipment.

However, Jishu Hozen does not mean that operators should independently perform complex repairs.

Activities such as electrical troubleshooting, major mechanical repairs, control-system modifications, or specialized maintenance should remain with qualified maintenance personnel.

The boundary between operator maintenance and specialist maintenance should therefore be clearly defined.

A good Jishu Hozen system creates cooperation between:

Operator + Maintenance + Production + Quality + Engineering

rather than transferring the entire maintenance responsibility to operators.

Why Is Autonomous Maintenance Important?

Machines often deteriorate gradually.

A bearing may begin making an unusual sound before failure.

A hydraulic system may start leaking before pressure becomes unstable.

A conveyor may develop abnormal vibration before a major breakdown.

A loose fastener may create repeated dimensional problems.

If these early signs are ignored, the problem may become more expensive and difficult to correct.

Autonomous Maintenance creates a structured method for detecting these abnormalities.

It helps move the organization from:

“Repair the machine after it breaks.”

toward:

“Maintain basic conditions and detect deterioration before failure.”

This preventive mindset is one of the important principles behind TPM.

Autonomous Maintenance and TPM

Total Productive Maintenance is a comprehensive approach to improving equipment effectiveness and involving different functions in equipment improvement.

TPM commonly includes several pillars, such as:

Autonomous Maintenance
Planned Maintenance
Focused Improvement
Quality Maintenance
Early Equipment Management
Training and Education
Safety, Health and Environment
Office TPM

Autonomous Maintenance is therefore one part of a broader TPM system.

It should not operate independently from the maintenance department.

Instead, Jishu Hozen supports the maintenance strategy by allowing operators to handle basic equipment care while maintenance specialists focus on more technical activities.

Main Objectives of Autonomous Maintenance

The primary objectives of Jishu Hozen include:

1. Prevent Equipment Deterioration

Regular cleaning, inspection, lubrication, and tightening help maintain basic equipment conditions.

2. Detect Abnormalities Early

Operators learn to identify abnormal conditions before they result in major failures.

3. Improve Equipment Reliability

Maintaining basic conditions can reduce avoidable equipment problems.

4. Reduce Unplanned Downtime

Early detection and preventive action can help reduce unexpected breakdowns.

5. Improve Operator Ownership

Operators become more aware of how their machines work and how equipment condition affects production.

6. Develop Employee Skills

Operators gradually develop basic equipment knowledge and abnormality-detection skills.

7. Support Zero Breakdown Goals

Autonomous Maintenance supports the broader TPM objective of improving equipment reliability.

The 7 Steps of Autonomous Maintenance

The traditional Autonomous Maintenance methodology is commonly explained through seven steps.

These steps provide a structured progression from basic cleaning and inspection toward greater operator ownership and continuous improvement.

The seven steps are:

Initial Cleaning
Eliminate Sources of Contamination and Inaccessible Areas
Establish Cleaning, Lubrication and Inspection Standards
Conduct General Inspection
Conduct Autonomous Inspection
Standardize Autonomous Maintenance
Autonomous Management

Let’s understand each step.

Step 1: Initial Cleaning

The first step is often called Initial Cleaning.

At this stage, the team thoroughly cleans the equipment and surrounding work area.

The purpose is not simply to make the machine look clean.

Cleaning provides an opportunity to inspect the equipment and discover hidden abnormalities.

During initial cleaning, teams may identify:

Oil leakage
Loose bolts
Damaged guards
Broken hoses
Worn belts
Abnormal vibration
Dust accumulation
Air leakage
Missing fasteners
Damaged cables

This leads to an important TPM principle:

Cleaning is inspection.

When operators clean equipment regularly, they become more familiar with its normal condition.

Step 2: Eliminate Sources of Contamination and Inaccessible Areas

After the initial cleaning, the team identifies the reasons why the equipment becomes dirty or difficult to inspect.

Examples include:

Oil leakage
Coolant leakage
Dust generation
Metal chips
Poor sealing
Difficult-to-reach lubrication points
Difficult-to-clean machine surfaces
Poorly positioned inspection points

The objective is to remove the source of the contamination instead of repeatedly cleaning the same problem.

For example, if a machine leaks oil every day, cleaning the oil every shift does not solve the root cause.

The better approach is to investigate:

Why is the oil leaking?

Possible causes may include:

Damaged seal
Loose connection
Worn component
Excessive pressure
Incorrect assembly

Correcting the source reduces both contamination and maintenance effort.

Step 3: Establish Cleaning, Lubrication and Inspection Standards

Once basic abnormalities have been addressed, the team develops clear standards.

These standards define:

What should be cleaned
Where it should be cleaned
How often it should be cleaned
What should be lubricated
Which lubricant should be used
Where lubrication should be performed
What should be inspected
Inspection frequency
Responsible person
Abnormality criteria

Visual standards are especially useful.

For example, a machine can have a simple lubrication map showing:

Lubrication Point → Lubricant Type → Quantity → Frequency

This reduces dependence on memory.

Step 4: Conduct General Inspection

At this stage, operators receive additional knowledge about machine components and their functions.

Training may cover:

Mechanical components
Electrical components
Pneumatic systems
Hydraulic systems
Lubrication systems
Sensors
Safety devices
Machine operating conditions

The objective is to help operators understand what normal and abnormal conditions look like.

For example, an operator may learn that a particular bearing normally operates with a certain sound and temperature.

If the condition changes significantly, the operator knows that it requires attention.

Step 5: Conduct Autonomous Inspection

Once operators have developed sufficient knowledge, routine inspection becomes part of normal work.

The operator may perform checks such as:

Oil level
Lubrication condition
Leakage
Loose components
Abnormal noise
Abnormal vibration
Pressure
Temperature indicators
Safety devices
Machine cleanliness

The inspection frequency should be practical and based on equipment requirements.

The objective is not to create excessive paperwork.

The objective is to create effective equipment care.

Step 6: Standardize Autonomous Maintenance

At this stage, Autonomous Maintenance activities become standardized.

The organization establishes clear procedures for:

Cleaning
Inspection
Lubrication
Tightening
Minor maintenance
Abnormality reporting
Escalation

Responsibilities should also be clearly defined.

For example:

Activity	Operator	Maintenance
Cleaning	Yes	Support
Basic inspection	Yes	Support
Lubrication	As defined by standard	Technical support
Abnormality reporting	Yes	Yes
Major repair	No	Yes
Electrical troubleshooting	No, unless specifically authorized	Yes
Equipment modification	No	Engineering/Maintenance

The exact responsibility should always depend on the organization’s training, risk assessment, and safety requirements.

Step 7: Autonomous Management

The final step focuses on continuous improvement and self-management.

The team should not simply continue performing the same checklist forever.

Instead, it should analyze equipment performance and identify opportunities for improvement.

Possible activities include:

Kaizen
Breakdown analysis
MTBF improvement
MTTR reduction
OEE improvement
Abnormality reduction
Visual management
Maintenance standard improvement
Operator skill development

At this stage, equipment care becomes part of the normal management system.

Autonomous Maintenance Example in an Automotive Factory

Consider an automotive stamping press.

The machine has several important components:

Press drive system
Die
Hydraulic system
Pneumatic system
Lubrication system
Sensors
Electrical controls
Safety devices

An Autonomous Maintenance program can be designed around these components.

Operator Daily Checks

The operator may check:

Oil leakage
Abnormal noise
Abnormal vibration
Lubrication condition
Air pressure indication
Machine cleanliness
Safety devices
Tool condition
Loose components

Maintenance Team Responsibilities

Maintenance specialists may handle:

Preventive maintenance
Electrical troubleshooting
Hydraulic repairs
Motor inspection
Bearing replacement
Control-system troubleshooting
Major component replacement

This creates a clear division of responsibility.

Autonomous Maintenance Example for CNC Machines

CNC machines can also benefit from Jishu Hozen.

Operators can perform routine checks such as:

Coolant level
Lubricant level
Hydraulic pressure
Air pressure
Chip accumulation
Machine cleanliness
Abnormal sound
Tool condition
Leakage
Basic visual inspection

Maintenance personnel can manage more technical activities such as:

Servo-system troubleshooting
Electrical diagnosis
Major spindle repair
Control-system repair
Preventive maintenance
Component replacement

Autonomous Maintenance and 5S

Autonomous Maintenance and 5S are closely related, but they are not the same.

5S primarily focuses on workplace organization and discipline.

Autonomous Maintenance focuses specifically on equipment care and operator involvement in maintaining basic equipment conditions.

5S activities can support Jishu Hozen by making abnormalities easier to see.

For example:

A clean machine surface makes oil leakage easier to detect.

A properly organized tool area makes missing tools immediately visible.

Clear identification makes abnormal conditions easier to recognize.

Therefore:

5S creates workplace discipline, while Autonomous Maintenance extends that discipline into equipment care.

Autonomous Maintenance and OEE

OEE, or Overall Equipment Effectiveness, is commonly used in TPM programs to evaluate equipment performance.

The traditional OEE framework considers:

Availability × Performance × Quality

Autonomous Maintenance can influence all three areas.

Availability

Early detection of abnormalities can help reduce unplanned downtime.

Performance

Well-maintained equipment can operate more consistently.

Quality

Stable equipment conditions can reduce equipment-related quality problems.

However, it is important not to assume that Autonomous Maintenance alone will automatically increase OEE.

OEE is influenced by many factors, including:

Equipment reliability
Production planning
Changeover
Material availability
Process capability
Quality
Operator practices
Maintenance strategy

Key Autonomous Maintenance Activities

A practical Jishu Hozen program can include the following activities.

Cleaning

Remove dirt, chips, oil, dust, and other contamination.

Inspection

Check equipment condition and identify abnormalities.

Lubrication

Maintain correct lubrication at designated points.

Tightening

Check appropriate fasteners and connections according to approved standards.

Abnormality Identification

Identify conditions that differ from normal.

Tagging

Use abnormality tags or another visual method to communicate problems.

Minor Corrections

Allow trained operators to perform approved minor activities within their defined responsibility.

Escalation

Ensure technical problems are quickly transferred to qualified maintenance personnel.

What Is an Abnormality Tag?

An abnormality tag is a visual method used to identify and communicate an equipment problem.

A tag may contain information such as:

Equipment number
Location
Date
Abnormality description
Person reporting
Responsible department
Action status

For example:

Equipment: Press-03
Abnormality: Hydraulic oil leakage near cylinder
Date: 16 August
Status: Maintenance action required

The purpose is not to create paperwork.

The purpose is to make abnormalities visible and ensure they are addressed.

Common KPIs for Autonomous Maintenance

Organizations can use several indicators to monitor Jishu Hozen effectiveness.

Useful indicators include:

Equipment Downtime

Measures the amount of time equipment is unavailable.

MTBF

Mean Time Between Failures measures the average operating time between failures.

MTTR

Mean Time To Repair measures the average time required to restore equipment after failure.

OEE

Overall Equipment Effectiveness provides a broader view of equipment utilization.

Abnormality Closure Rate

Measures how effectively identified abnormalities are resolved.

Repeat Failure Rate

Tracks whether the same problems continue to occur.

Autonomous Maintenance Compliance

Measures whether planned routine activities are being completed.

Breakdown Frequency

Tracks the number of equipment breakdowns over a defined period.

Common Mistakes in Autonomous Maintenance

Although Jishu Hozen can be highly effective, implementation can fail if the program is treated as a checklist exercise.

1. Treating Cleaning as the Final Objective

A clean machine is not necessarily a reliable machine.

Cleaning should help identify and eliminate abnormalities.

2. Giving Operators Too Much Responsibility

Operators should not be expected to perform technical maintenance beyond their competence and authorization.

Safety and competency must always come first.

3. Creating Excessive Checklists

If the checklist becomes too complicated, employees may focus on completing paperwork rather than maintaining equipment.

4. Ignoring Abnormalities

Reporting an abnormality is not enough.

There must be an effective system for correcting it.

5. No Maintenance Support

Autonomous Maintenance does not replace the maintenance department.

Maintenance specialists remain essential for technical diagnosis, preventive maintenance, repairs, and equipment improvement.

6. No Standardization

If each operator follows a different method, the equipment-care system becomes inconsistent.

7. Measuring Only Checklist Completion

Completing 100% of inspections does not necessarily mean the equipment is healthy.

The organization should also monitor actual equipment performance.

How to Implement Autonomous Maintenance Step by Step

A practical implementation can follow this sequence.

Step 1: Select a Pilot Machine

Choose a machine with clear improvement opportunities.

Step 2: Establish the Current Condition

Document:

Breakdown history
Downtime
Existing abnormalities
Cleaning condition
Lubrication condition
OEE
Repeat failures

Step 3: Conduct Initial Cleaning

Clean the equipment thoroughly and identify abnormalities.

Step 4: Tag Abnormalities

Clearly identify problems requiring action.

Step 5: Eliminate Sources of Contamination

Fix leaks and other causes of repeated contamination.

Step 6: Develop Standards

Create simple standards for:

Cleaning
Inspection
Lubrication
Tightening
Abnormality reporting

Step 7: Train Operators

Train operators on:

Machine components
Basic functions
Abnormality identification
Safe maintenance boundaries
Escalation procedures

Step 8: Establish Routine Inspection

Integrate the activities into normal work.

Step 9: Review Equipment Performance

Monitor:

Breakdown
Downtime
MTBF
MTTR
OEE
Repeat abnormalities

Step 10: Expand the Program

Once the pilot is stable, extend the methodology to additional equipment.

Operator Training for Autonomous Maintenance

Training is one of the most important factors in successful Jishu Hozen implementation.

Operators should understand:

Machine Basics

What the machine does and how its major components work.

Normal Conditions

What normal sound, vibration, temperature, pressure, and appearance look like.

Abnormal Conditions

What changes require attention.

Inspection Methods

How to perform approved checks correctly.

Safety

Which activities are safe for operators and which require authorized maintenance personnel.

Escalation

Who should be contacted when an abnormality is identified.

A trained operator is more likely to identify deterioration before it becomes a major problem.

Autonomous Maintenance and Safety

Safety should never be compromised for the sake of maintenance productivity.

Operators should not perform activities that require specialized authorization unless they are properly trained, authorized, and the organization’s procedures permit them.

Important safety considerations may include:

Lockout/Tagout or applicable energy-isolation procedures
Electrical safety
Pneumatic energy
Hydraulic pressure
Stored mechanical energy
Hot surfaces
Moving machinery
Machine guarding
Chemical exposure

Cleaning or inspection activities should be designed so that employees can perform them safely.

Autonomous Maintenance in Different Industries

Jishu Hozen is not limited to automotive manufacturing.

It can be applied to:

Automotive
Sheet metal manufacturing
Stamping
Injection molding
CNC machining
Welding
Assembly
Packaging
Food processing
Pharmaceuticals
Electronics
Logistics
Warehousing

The exact activities will vary according to the equipment and industry.

For example, lubrication may be important for a mechanical machine, while cleanliness and environmental conditions may be more important in certain electronics processes.

Autonomous Maintenance vs Preventive Maintenance

These two concepts are related but different.

Autonomous Maintenance

Usually focuses on basic equipment care performed by trained operators.

Examples:

Cleaning
Basic inspection
Lubrication
Abnormality detection

Preventive Maintenance

Usually involves planned maintenance activities performed by maintenance specialists or authorized personnel.

Examples:

Component replacement
Detailed inspection
Calibration
Electrical testing
Major servicing

The two systems should work together.

Operators maintain basic conditions.

Maintenance specialists maintain technical reliability.

Autonomous Maintenance vs Predictive Maintenance

Predictive Maintenance uses equipment-condition information to determine when maintenance may be required.

Examples include:

Vibration monitoring
Thermography
Oil analysis
Sensor-based monitoring

Autonomous Maintenance is generally more focused on basic operator-led care and early abnormality detection.

They are not competing approaches.

A mature maintenance system may combine:

Autonomous Maintenance + Preventive Maintenance + Predictive Maintenance + Corrective Maintenance

Benefits of Autonomous Maintenance

A well-designed Jishu Hozen program can provide several benefits.

Reduced Breakdown Risk

Early abnormality detection can help prevent some failures.

Better Equipment Condition

Regular cleaning, inspection, and lubrication help maintain basic conditions.

Improved Operator Knowledge

Operators understand their equipment better.

Faster Abnormality Detection

Problems can be identified closer to where they occur.

Improved Cooperation

Production and maintenance teams work together more effectively.

Reduced Maintenance Cost

Preventing deterioration can reduce the cost associated with major failures.

Improved Workplace Discipline

Regular equipment care can strengthen workplace standards.

Better Equipment Availability

Stable equipment conditions can contribute to improved availability.

Practical Autonomous Maintenance Checklist

A simple checklist can be developed based on the equipment.

For example:

The actual checklist should be customized to the machine rather than copying the same list for every piece of equipment.

Frequently Asked Questions

What is Autonomous Maintenance in TPM?

Autonomous Maintenance is a TPM approach in which trained machine operators perform basic equipment-care activities such as cleaning, inspection, lubrication, and abnormality detection.

What does Jishu Hozen mean?

Jishu Hozen is the Japanese term commonly used for Autonomous Maintenance or self-maintenance.

What are the seven steps of Autonomous Maintenance?

The seven commonly recognized steps are Initial Cleaning; Eliminate Sources of Contamination and Inaccessible Areas; Establish Cleaning, Lubrication and Inspection Standards; General Inspection; Autonomous Inspection; Standardization; and Autonomous Management.

Does Autonomous Maintenance replace the maintenance department?

No. Autonomous Maintenance complements specialist maintenance. Operators handle defined basic equipment-care activities, while maintenance professionals continue to perform technical maintenance and repairs.

What is the role of operators in Jishu Hozen?

Operators are responsible for maintaining basic equipment conditions, identifying abnormalities, following approved inspection standards, and reporting problems that require specialist support.

How does Autonomous Maintenance improve OEE?

By supporting better equipment condition and early abnormality detection, Jishu Hozen can contribute to improved availability, performance, and quality. However, OEE is affected by many factors, so Autonomous Maintenance alone does not guarantee an OEE increase.

Is Autonomous Maintenance applicable to CNC machines?

Yes. CNC operators can perform approved routine activities such as cleaning, basic inspection, checking coolant and lubricant levels, identifying abnormal sounds or vibration, and reporting abnormalities.

What is the difference between Jishu Hozen and Preventive Maintenance?

Jishu Hozen focuses primarily on basic operator-led equipment care, while Preventive Maintenance involves planned maintenance activities designed to prevent equipment failures and is often performed by maintenance specialists.

Final Thoughts

Autonomous Maintenance, or Jishu Hozen, is based on a straightforward idea: equipment should be cared for every day, not only when it breaks down.

However, successful implementation requires more than asking operators to clean machines.

The real purpose of Jishu Hozen is to develop a culture in which operators understand their equipment, recognize abnormal conditions, maintain basic conditions, and communicate problems quickly.

The seven-step approach provides a structured path:

Initial Cleaning → Eliminate Contamination Sources → Establish Standards → General Inspection → Autonomous Inspection → Standardization → Autonomous Management

When combined with Planned Maintenance, Kaizen, 5S, OEE, Quality Maintenance, and other TPM practices, Autonomous Maintenance can become an important part of a reliable manufacturing system.

The ultimate objective is not simply a cleaner machine.

It is a machine that is better understood, better maintained, easier to inspect, safer to operate, and less likely to develop uncontrolled deterioration.

For production and maintenance teams, that shift in thinking can make a significant difference.