Checklist C

Award for TPM Excellence - Category B

Categories Check Points

1 TPM Policies TPM policies are planned in relation between company policies and plant/factory policy.
and The relation between TPM target values and management target results are clear.
Objectives
The master plan is in an appropriate order as an action plan to achieve TPM.
TPM policies and objectives are checked using methods such as benchmarking that all sections of PQCDSME are
displayed corresponding to 8 pillars.
TPM policies and objectives have been set forth and observed by all the departments and sections.
The achievement status of TPM policies and objectives is available in a time line using objective data.
Overlapping small groups, the TPM promotion committee, and other special committees are organized in a way that
leads to TPM activities.
TPM promotion units help facilitate TPM activities within departments/sections.
Small groups on the front line have been vitalized.
The achievement status of TPM objectives is confirmed and necessary actions are taken for unachieved indexes.
2 Individual Individual improvement issues and themes are set up in relation to TPM policies and objectives.
Improvement Objectives are set forth for each subject of individual improvement, and contributions are being made clear by
performance indexes.
Terms and definitions are being made clear on production department losses and their elimination is being dealt with.
A system is set up to analyze and understand the relationship between loss and cost using the loss map and loss tree
methods.
Improvement activities are being actively carried out, and contribution to the achievement index is clearly understood.
A system to prevent recurrence of problems such as defects, breakdown, and short mechanical stalling is standardized.
A system to apply cases of individual improvement horizontally is established.
There are many cases of zero occurrences of defects, breakdown, and short mechanical stalling.
Many necessary improvement measures, such as the QC method, Nazenaze analysis, and PM analysis, are used
effectively and the custom of thinking with rationales and principles is being established.
The results of improvement are being announced qualitatively and in terms of PQCDSME, and future issues and goals
are clearly set.
3 Autonomous Autonomous maintenance achievement goals are set up using a step-by-step method.
Maintenance Achievement goals are appropriately assessed at each step by managers for progress and completion.
Workplace/on-site visual boards, which show the status of activities, goals, accomplishments, and issues to be resolved,
are in place.
Actions are being taken to remove dirt, stains, scattered raw materials, oil leakage, etc. and to eliminate their cause.
Cleaning, lubrication, bolt tightening, and inspections are performed perfectly and without fail, and thorough measures
are taken for difficult-to-handle areas.
Excellent storage procedures are in effect for tools and jigs, and cleaning is carried out routinely.
Improvement proposals are made and implemented.
A system to upgrade the skills of all employees is established with a skill evaluation chart, one-point lessons, and
maintenance skill training, and is showing results.
One-point lessons are available as training texts and are being used.
Employee morale surveys and skill maps are used to confirm that all employees are working on workplace improvement
with a sense of accomplishment.
4 Planned Goals for autonomous maintenance are set up in line with TPM policies.
Maintenance Duties for autonomous maintenance and planned maintenance are clearly defined and a mutual cooperative structure is
established.
Appropriate equipment diagnosis technologies are being put to use for predictive maintenance and deterioration checks,
and TBM (time-based maintenance) and CBM (condition-based maintenance) are selectively used.
 Maintenance standards are in order and an appropriate maintenance calendar is created.
Sudden breakdown has significantly decreased with thorough failure analysis and enhanced improvement maintenance;
a system is set up for MP design information to accumulate and utilize the data.
A system is set up and is being upgraded for professional maintenance skills such as repair skills, inspection skills,
lubrication control skills, and failure analysis skills, for which a sufficient technical level has been reached.
Spare parts, molds jigs, fixtures, measuring equipment, drawings, etc. are all stored as data.
Maintenance information on the status of equipment deterioration, failure, equipment shutdown, maintenance man-
hours, etc. is stored and utilized.
Maintenance technology training is provided, and maintenance men are obtaining certification as equipment
maintenance engineers.
Maintenance costs are being adequately budgeted and controlled, and the maintenance cost ratio is monitored.
5 Quality Goals for quality maintenance are set up in line with TPM policies.
Maintenance Data are being accumulated for defect outflow and defect process, causes are being analyzed, and improvement goals
are being set up.
A system is structured to set up requirements for equipment that will not turn out defects, and maintenance control is
performed appropriately.
For quality defects, measures are taken to prevent recurrence from the aspect of 4M.
Various analytical methods such as Pareto analysis, QM matrix, and PM analysis are effectively used at the appropriate
stages.
Based on fundamentals and principles, quality defects are being analyzed for cause.
Measures aiming for zero occurrences of quality defects are showing results.
A measure is set up to effectively and thoroughly applies the brakes on defect recurrence.
A system is established to set up a quality maintenance system with figure 8 deployment.
In order to reduce the defect rate caused by equipment, necessary training and research are moving forward.

Checklist C
Award for TPM Excellence - Category B
Award for TPM Excellence - Category A
Award for Excellence in Consistent TPM Commitment
 Categories Check Points
6 Product and Goals for development and control of plants and products are set up in line with TPM policies.
Equipment Items of development and control of plants and products and their standards are clear and the progress is
Development monitored.
and Control
In product and plant development management, a system that extracts the origin of problems in design review and
debugging is fully functioning.
The structure generating loss for product development management is clear and improvement measures are put in
place.
The MP design approach and the implementation of equipment, molds, jigs, and fixtures are both systemized.
An information feedback system for MP design is in place.
Economic comparison and risk analysis of plant investment plans are carried out appropriately for the cash flow
base.
A design method based on assessment standards for ease of production is introduced.
Initial phase control is being exercised on new products and equipment, and there is a positive case.
There is a case in which development of new technology and processing has led to the development of new
products and equipments.
7 Training and Goals for training programs are qualitatively set up.
Development Important themes for the training programs are interlinked with the future plans of the company.
A systematic training program for each job and rank is established with employees having a full understanding of the
required knowledge and skills for each job and rank.
A training curriculum and lecturers are available based on the training system, and appropriate training is provided.
Effective training programs are set up for managers, staff members, operators, and maintenance workers.
A place for maintenance skill training is provided and utilized for professional maintenance training and operator
training, making it possible to carry on the skills.
OJT training programs are fully functioning leading to the upgrading of skills for all staff members and progress in
multi-skilled worker training.
Staff members are actively working to obtain certification as autonomous maintenance engineers and equipment
maintenance engineers.
Employee satisfaction and the status of motivation are quantitatively analyzed and measures are in place for their
enhancement.
Results from the human resources program are being fed back to TPM activity, and achievement is understood.
8 Administrative Goals for administrative and supervisory departments are set up in line with TPM policies.
and By supporting the efficacy of production activity and improvement of supplier activity, the product inventory and
Supervisory
goods in process have been reduced.
Departments
Losses by the administrative and supervisory departments are accurately measured.
Significant reduction in man-hours has led to a reduction in overtime and work on holidays, which has reduced fixed
administrative costs.
A multi-disciplinary and multi-skill approach has moved forward, and man-hours for different departments are
becoming equal.
Morale is being enhanced in the administrative and supervisory departments.
The office supply inventory is kept at a minimum and the office environment is improved.
An information system is being structured and a system is set up for quick and accurate information transmission.
Each department is dealing with reducing costs incurred from operations and overall cost reduction is improving.
A system to carry over the skills required for sustainable operation maintenance is in place.
9 Safety, Safety, sanitation, and environment control policies are well defined, improvement targets are set for reduction in
Sanitation waste and emissions, etc.
and Past cases of labour accidents and plant disasters have been scientifically analyzed, and action has been taken to
Environmenta prevent recurrence.
l
The Industrial Safety and Health Law is being complied with and the work environment (noise, vibration, dust, light,
Control
etc.) meets the legal standards.
A risk analysis hazard map of the entire plant has been created, and the safety inspection manual is in order and is
 being audited.
Safety awareness improvement activities take place regularly with near accident, KY and other measures.
An emergency manual is in place, protective equipment and lifesaving equipment are ready to use, and emergency
drills are being executed.
Safety devices such as safety covers, safety nets, safety signage, and foolproof disaster prevention measures are
appropriately prepared.
Safety assessment is enforced before introducing new equipment and/or process.
Results from improvement activities have led to energy and resource conservation.
Environmental measures such as risk management and waste management are being considered, moving forward
targeting zero emissions and reduced environmental load.
10 Effects and The level of achievement for the TPM goal is being assessed, and cause analysis is being carried out for its
Evaluation of achievement or non-achievement.
TPM Objectives are being met in terms of overall equipment effectiveness, sporadic breakdowns, minor stoppages, and
defective product indexes.
Prominent results have been obtained in reducing process defects and customer complaints.
The product inventory and works in process have been drastically reduced in comparison to before TPM
introduction.
A record of zero accidents and zero pollution is continuing.
Product cost is reduced, and cash flow is improved.
Achievement is seen that contributes to the operation profit improvement.
TPM cost/benefit analysis is in order.
High worker morale and a stimulating working environment are in place as an intangible benefit of TPM activities.
Problems that remain unsolved in connection with TPM activities are being clearly recognized and concrete action
plans are being envisioned.