An outlet of an electrical cabinet has small piece of hazard tape attached and as crude as it maybe you can now tell when walking past if the filters are blocked on the inlet vents. The green circle is a task point for a TPM check.

Cleaning station

This cleaning station shadow board is mounted inside the machine cell and means that on machine stoppages small routine cleaning tasks can be carried out without having to go and find cleaning materials. Normally the operators would have spent 10 minutes of more gather up the required material prior to small visual cleaning jobs taking place.
All cleaning jobs are broken up into small 5 - 10 minute chunks that can be slotted in around natural stoppages throughout the week and followed on a TPM T Card board.

Colour coded lubrication points

Here all the lubrication points on the machine are marked up colour coded and numbered so TPM lubrication routines can be carried out easily by operators or maintenance. Each machine has a corresponding A3 lubrication map at its information point for all lube point on the machine.


The lubrication map follows the 5R lubrication principle. RIGHT point / RIGHT lube / RIGHT quantity / RIGHT frequency / RIGHT method.

CIL (Cleaning, Inspection and Lubrication) point labelling

This is an example of how to best show where certain Cleaning / Inspection / Lubrication points are during a maintenance or TPM routine.


The numbered points correspond to checks detailed on Standard Work instruction and helps personnel find the correct points easier and faster ensuring the right work gets carried out.

Adjustable sensor positions

Here the proximity sensors are on adjustable slots that where designed into the plate by the OEM to help with initial setup of the machine. They positions should never need change, if they do its likely because that something is worn and hence the worn item should be changed out.
The plate could also be re-engineered with fixed holes however the small blue arrow markings show exactly where each sensor should sit if they ever need changed in future.

Electrical cabinet labelling

This was in an installation of a new machine where originally nothing was labelled. All the cabinet componenets were sunsquently labelled for there function and all lidding was labelled so in the event of it ever being removed it would be put back in the correct place for the compoent labelling to make sense.


It is planned to go one step further and also show the correct ampage set points for all the MCB's. How many times have we gone to machinery with a motor burnt out only to find somebody in their wisdom had turned up the trip to stop those nuisience faults.

Hydraulic tank sight glass mark up

The tank sight glass marked up to show where an acceptable level is allowed and what point the low level alarm and cut out kicks in. The technicains and operators know that they do not need to top up until the oil gets close to the bottom of the green band. Previously they either were topping up too regularly is the system was losing oil through small leaks or they assumed that as long as there was oil in the sight glass it would be ok. An oil level close to the bottom of the sight glass kicks in the minimum level alarm and then the low level machine stop.