Operator daily machine care (autonomous maintenance) checklist

Most small breakdowns on a sewing floor start with lint, missing oil, a bent needle or a wrong threading path - things the operator sees first. Autonomous maintenance (Jishu Hozen in TPM) gives the operator ownership of these basics.

The daily checklist

Start of shift (3-4 minutes)

• Brush lint from the feed dog, hook and under the needle plate.
• Look at the oil window - level between the marks.
• Check the needle: straight, sharp, correct size and point.
• Sew a test piece on scrap fabric; check stitch, tension and SPI.

During the shift

• Change the needle when it is blunt or after any knock.
• Report unusual noise, heat, smell or oil leak immediately.
• Keep thread stand, guides and tension discs clear.
• Let the feed dog move the fabric - pulling causes needle breaks and uneven stitches.

End of shift (3-4 minutes)

• Blow or brush lint, wipe the table and machine head.
• Needle and presser foot down; switch off the motor.
• Cover the machine. Write any problem on the machine tag for the mechanic.

How to introduce it (TPM steps, simplified)

1. Initial clean - mechanics and operators clean machines together and tag every problem found (red tag = mechanic, white tag = operator can fix).
2. Fix sources of dirt - lint covers, oil drip trays, better thread stands.
3. Set standards - a one-page picture checklist at each machine, in Bangla.
4. Train and check - supervisors check 5 machines per line per day and score them.
5. Sustain - include machine care in operator skill matrix and line 5S audits.

Tip: Make the checklist pictures, not words: a photo of a clean hook area is clearer than a paragraph.

What to measure

Key points

• Ten minutes of daily care prevents most small stops.
• Operators clean, inspect and report; mechanics repair.
• Use picture checklists and daily audits to make it stick.