LEAN MASTER CLASS

TPM Forms

TOTAL PRODUCTIVE
EFFECTIVENESS

Process:

Team:

Location:

Date:

Availability Rate: (Equipment failure, Set-up & adjustment, Tool change, Start-up)
Available Time

- Down Time

= Availability Rate % =

Available M/C Time

Performance Rate:
Standard Time

(Minor stops & idling, Speed loss)

x Units made

= Performance Rate % =

Operating Time

Quality Rate:

(Scrap & rework)

Parts Count

- Defects

= Quality Rate % =

Parts Count
Alternatives:

Performance Rate = (Op Time - Perf. loss)/OpT

Quality Rate = (Productive time - Defect time)/Prod Time

=
TPE % =

Quality Loss

Scrap/Rework

Perform. Loss

Speed loss

Stops/Idling

Avail. Loss

Start-up loss

Tool Change

Set-up/adjust

Equip Failure

Run Time

End

Start

TPE OBSERVATION
Equip.:
Name:

Part:
Date:

Remarks

Department:

Machine:

Time After

Time Before

Job begins
on the

Job ends
on the

Time After

Time Before

Job begins
on the

Job ends
on the

Time After

Time Before

Job begins
on the

Job ends
on the

Time After

Time Before

Job begins
on the

Job ends
on the

Time After

Time Before

Job begins
on the

Job ends
on the

Improvement
Measurement

Improvement
Dates

Responsible for follow-up

Problem Description and suggested improvement

Process owner

Scrap &
Rework

Idling,
minor
stoppages
and speed
loss

Set-up &
Adjustment

Tool
Change

Breakdowns,
Start-up

Eater

Date:

Effectiveness Improvement Sheet

TPM
CLEANING LIST

M/C:

Team:

Location:

Date:
RESULTS

CATEGORY
(1)

POINTS Initial

ITEMS TO CHECK
1. Any dirt, dust, excess oil, rubber chips, foreign objects?

(a) Moving parts, rotating parts

CLEANING OF
MAIN BODY OF
MACHINE

(2)

(b) Braking apparatus, locking mechanism

(c) Guides, fixtures
(d) Frame, bed surface
2. Any nuts, bolts, etc. loose, wobbly, missing?

10

3. Any play in moving parts, fixture mounting section, etc?

10

4. Any unneeded objects on body of machine?

5. Is machine firmly seated?

1. Dirt, dust, excess oil, rubber chips, foreign objects, damage:

(a) Cylinders, solenoid valves, air, 3-point sets

CLEANING OF
AUXILIARY
DEVICES

(b) Limit switches

(c) Motors, reduction gears, propeller shafts, couplings
(d) Meters, displays, switches, control boards (int/ext)
(e) Wiring, piping
2. Are nuts, bolts, etc. loose, wobbly, missing?

10

3. Any leaks of oil, water, air, gas, steam?

4. Any indicator lamps out?

(3)
LUBRICATION
(4)
5Ss AROUND THE
MACHINE

(5)
STATUS OF
ACTIVITIES

1. Does oil reach sliding parts?

10

2. Is there the right amount of oil in (1)lubricator? (2) oil tank?

3. Do oil holes have caps ? (1) lubricator (2) oil tank

4. Are oil supply pipes clean, with no leaks or seepage?

1. Tools, instruments in assigned places ? None missing, damaged?

2. Are all name plates and labels clean and clearly visible?

3. Are covers and safety shields free of dirt, dust, fog ?

4. Are wires and pipes clean and clearly visible?

5. Any dirt, dust around machine? Dust from top of machine?

6. Any parts, trash, cigarette butts, plastic bags on floor ?

7. Any extraneous items or outdated posted matter?

8. Are good parts, rejects and scrap material clearly separated?

1. Are Kaizen examples, goals and results clearly posted on activities board?

2. Do plans address problem causes, cleaning difficulties ?

3. Are daily checks carried out ?

3
TOTAL ->

MISC.

1. Any damage to safety devices, enclosures, shields?

100 pts
yes/no

TPM - SOURCE OF
PROBLEMS CHECKLIST

M/C:

Team:

Location:

Date:
RESULTS

CATEGORY

ITEMS TO CHECK

POINTS

(1)
INITIAL
CLEANLINESS
MAINTENANCE
(2)
ELIMINATION OF
THE SOURCES
OF UNTIDINESS
AND
ABNORMALITIES

(3)

Did we maintain the equipment in the state of cleanliness obtained after this initial cleaning ?

Have the contaminating sources such as dust, dirt, oil, splashes, chips and others been
identified and presented on the board ?

Did we take corrective measures to resolve the sources of dust, dirt, oil, splashes
and chips, etc.?

3
4
5
1

Did we take the appropriate measures to eliminate oil, water, air, gas leaks ?
Do we have an action plan (responsibility and deadline) to handle the remaining problems ?
Did we forget any sources of problems?
Did we catalogue the hard-to-reach areas and indicate the progress
accomplished?

5
5
5

Did we improve the hard-to-reach areas?

A Did we create or acquire cleaning tools?
B Did we improve the removal or replacement or the covers and guarding?

Is the nature of the improvements implemented/planned to simplify and

shorten the cleaning time ?

1
2
3

Do we have an action plan (responsibility and deadlines) to handle the remaining problems ?
Did we forget the hard-to-reach areas?
Did we set deadline objectives for the different basic cleaning, lubrication and
inspection activities?

4
5
6

Did we define and create the cleaning, lubrication and inspection norms ?
Do we perform daily checks?
Are the improvement and objectives published on the TPM communication board ?

Have the corrective actions been made for each abnormality identified at the
initial cleaning ?

ACCESS
IMPROVEMENT

(4)
ACTIVITIES
MANAGEMENT

(5)
INITIAL
CLEANING
FOLLOW-UP

10

5
5
10
5
5
5

10

TOTAL ->

100

Initial

Marked
bolts:

Abnormalities
identified:

Maintenance alone and tightening

mark (red dot, white line)

Verify tightening daily (yellow dot,

white line)

Critical or subject to loosening

(yellow dot)

Damaged
nut

Damaged
head

Loosened
nut

Crooked
bolt

Bolt too
short

Maintenance only
(red dot)

Total verified:

Total

Total

Total

Total

Total

Missing without consequence

(yellow circle)

OTHERS

Misaligned
nut

Misaligned
bolt

Missing
nut

Missing
bolt

Broken
bolt

Verified but non critical

(white dot)

Total

Total

Total

Total

Total

Abnormalities identifier: screws, nuts and bolts

ITEM

ACTION

Machine

* Upon a power shutdown, apply padlocking standards

10

10

No

Line

CHECK LIST (AUTONOMOUS MAINTENANCE)

/

Frequency:see example on back

Frequency Duration Who

Build Year

page

Month:

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Date

Inspected by

D2

W3,D1

M6, W1, D2

Daily inspection

Weekly inspection

Monthly inspection

Yearly inspection

(on the 6th month,

the first week of that month,
the second day of the week)

(on the third week,

first day of that week)

(on second day of the week)

(Daily)

Inspection frequency example

Day

Fill the report daily

Day

31

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

Day

CODE

CODE

Norm. Temp.

Hydraulic
Oil

Norm. Temp.

Hydraulic
Oil

CODE

CODE

Norm. Temp.

Lubrication
Oil
CODE

CODE

Gear Oil

Gear Oil

Department

Machine Code

Month/Year

Norm. Temp.

Lubrication
Oil

Indicate the quantity used

Specify:
litres: l
millilitres: ml

Daily lubricant log book

CODE

CODE

Grease

Grease

TPM RESULTS SHEET

M/C:

Team:

Location:

Date:

Total Productive Effectiveness

Abnormalities identified

Beginning of event

Total identified

End of event

Accessibility issues identified

Capability
Beginning of event

End of event

Total identified

Corrected

Sources of problems score

Cleaning score
Beginning of event

Corrected

End of event

Beginning of event

Pictures
Before

After

End of event

TPM IMPROVEMENT SHEET

RAISED BY:

Equipment:

TPM Tag No.

CONTAMINATION
SOURCE

Location:

Date:

HARD-TO-REACH
AREA

__________________________________________

PROMISED BY:

RESPONDENT: __________________________________________
LAYOUT

__________________

DELIVERED ON: __________________

PROBLEM:

IMPROVEMENT:

Attach to the requests for service

TPM
Date of Inspn

INSPECTION TAG
No.:

Inspector

TPM
Date of Inspn

INSPECTION TAG
No.:

Inspector

TPM
Date of Inspn

INSPECTION TAG
No.:

Inspector

TPM
Date of Inspn

Machine Name & Number

Machine Name & Number

Machine Name & Number

Description of Malfunction

Description of Malfunction

Description of Malfunction

Description of Malfunction

Corrective Action

Corrective Action

Corrective Action

Corrective Action

TPM
Date of Inspn

Completed
(tick)

Person Responsible

INSPECTION TAG
No.:

Inspector

Planned Date
of Action

TPM
Date of Inspn

Completed
(tick)

Person Responsible

INSPECTION TAG
No.:

Inspector

Planned Date
of Action

TPM
Date of Inspn

Completed
(tick)

Person Responsible

INSPECTION TAG
No.:

Inspector

Planned Date
of Action

Machine Name & Number

Machine Name & Number

Machine Name & Number

Description of Malfunction

Description of Malfunction

Description of Malfunction

Description of Malfunction

Corrective Action

Corrective Action

Corrective Action

Corrective Action

Person Responsible

Completed
(tick)

Planned Date
of Action

Person Responsible

Completed
(tick)

Planned Date
of Action

Person Responsible

Completed
(tick)

Planned Date
of Action

INSPECTION TAG
No.:

Inspector

Machine Name & Number

Planned Date
of Action

Completed
(tick)

Person Responsible

TPM
Date of Inspn

No.:

Inspector

Machine Name & Number

Planned Date
of Action

INSPECTION TAG

Person Responsible

Completed
(tick)

TPM

INSPECTION TAG
No.:

TPM

INSPECTION TAG
No.:

TPM

INSPECTION TAG
No.:

TPM

Date of Inspn Inspector

Date of Inspn Inspector

Date of Inspn Inspector

Date of Inspn Inspector

Machine Name & Number

Machine Name & Number

Machine Name & Number

Machine Name & Number

Description of Malfunction

Description of Malfunction

Description of Malfunction

Description of Malfunction

Corrective Action

Corrective Action

Corrective Action

Corrective Action

Completed
(tick)

Planned Date Person Responsible

of Action

TPM

INSPECTION TAG
No.:

Completed
(tick)

Planned Date Person Responsible

of Action

TPM

INSPECTION TAG
No.:

Completed
(tick)

Planned Date Person Responsible

of Action

TPM

INSPECTION TAG
No.:

TPM

Date of Inspn Inspector

Date of Inspn Inspector

Date of Inspn Inspector

Machine Name & Number

Machine Name & Number

Machine Name & Number

Machine Name & Number

Description of Malfunction

Description of Malfunction

Description of Malfunction

Description of Malfunction

Corrective Action

Corrective Action

Corrective Action

Corrective Action

Completed
(tick)

Planned Date Person Responsible

of Action

Completed
(tick)

Planned Date Person Responsible

of Action

Completed
(tick)

No.:

Completed
(tick)

Planned Date Person Responsible

of Action

Date of Inspn Inspector

Planned Date Person Responsible

of Action

INSPECTION TAG

Planned Date Person Responsible

of Action

INSPECTION TAG
No.:

Completed
(tick)