TPM Checklist

1. Policy and objectives

How is equipment management integrated into company policy? Are equipment management policy and objectives set and prioritized correctly? Are the management guidelines and evaluation criteria stipulated? Are long-term and annual plans integrated? Are policy and objectives thoroughly understood and implemented? Are accurate checks done to make sure objectives are being met? Are the years results considered in formulating goals, objectives and plans for the next year?

2. Organization and operation

Are the organization and personnel assignments right for managing the equipment? Is a good organization in place for promoting TPM? Is the TPM promotion organization in close contact with production lines? Are all the necessary departments participating fully in TPM? Is effective co-ordination being done between the head office and the factories? Are there any impediments to the exchange and use of information? Are relations good with any subcontractors responsible for equipment, dies, tools and maintenance work?

3. Small-group activities and autonomous maintenance

Is the organization of the small groups right? How are small-group activity objectives set? Do the groups meet frequently and are their meetings lively? Are there lots of good suggestions, and are they handled properly? How is goal attainment ascertained? Do operators take the initiative in maintaining their equipment?

4. Training

Do the different departments understand TPM? Are the training programmes broad enough and their curricula right? Do the training programs follow the curricula? How many people have technical or expert certifications? How knowledgeable and skilled are people in maintenance techniques? How is skill assessment done? Is there any way to make sure the training is having an effect?

5. Equipment maintenance

Are the 5-S being implemented? - Is the machinery clean and free of dust, filings, oil and other waste material? - Have policies been instituted to deal with dirt, places that cause soiling and places that are difficult to clean, inspect and lubricate? - Are lubrication labels, gauge limitations, bolt tighten-to-her marks and other visible indicators used? - Are all of the tools, materials, gauges and other things stored neatly and kept clean?

6. Equipment maintenance

Are equipment diagnosis techniques used in these cases? - Cracking, corrosion and loosening? - Abnormal vibration, heating and noise? - Water, oil, gas and air leakage? Are power lines, water lines, hydraulic lines and other lines neatly and properly handled? Are oils properly selected and properly replaced or filtered at the appropriate intervals?

7. Planning management

Are the appropriate efforts being made to improve maintenance techniques and efficiently? Are the equipment standards properly set and enforced in a planned manner? Are monthly and annual maintenance plans drawn up and implemented properly? Are the purchasing plans for spare parts and other maintenance equipment properly drawn up (e.g.. How much of what to buy from where) and are such things cared for? Are equipment blueprints well cared for? Are the dies, tools and gauges properly cared for?

Planning management...

Are good records being kept on equipment wear and equipment failures that mandate stoppages or other maintenance efforts? Are maintenance records used to improve processes? Are the right maintenance techniques properly applied?

8. Equipment investment plans and maintenance planning

Is equipment investment co-ordinated with the development of new products and new processes? Is equipment investment cost-effective? How is the plant investment budget drawn up and controlled? Are maintenance planning suggestions duly reflected in equipment investment standards? Are reliability and maintenance duly considered in selecting, designing and placing equipment?

Equipment investment plans and maintenance planning...

Is equipment closely monitored in the start up stages Is the company good at developing its own dies, tools and equipment? Are pollicies promptly instituted to keep major problems from recurring? Are plant assets properly managed?

9. Production volume, scheduling, quality and cost

Is the equipment control closely integrated with production volume and scheduling? Is equipment control closely integrated with quality control? Are maintenance budgets drawn up and managed properly? Is the energy and other resource conservation practiced?

10. Safety, sanitation and environmental conservation

Are sound policies in place for safety, sanitation and environmental conservation? Are the right organizations in place for safety, sanitation and environmental conservation? Are safety, sanitation and environmental conservation methods known and practiced? Is the equipment investment integrated with safety, sanitation and environmental conservation considerations? Are safety and sanitation policies paying off? Do environmental pollicies meet all of the legal requirements?

11. Results and assessments

Are results properly measured? Are policies being implemented and objectives met? Is maintenance paying off in terms of enhanced productivity and other management aims? Does the company make an effort to publicize its activities and its successes? Does the company know where the problems are? Have plans been drawn up for future progress?