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
X
(Minor stops & idling, Speed loss)
x Units made
= Performance Rate % =
Operating Time
Quality Rate:
X
(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
====>>>
Cycle
10-
9-
8-
7-
6-
5-
4-
3-
2-
1-
Actual pos.
Total
Average (accuracy)
Stray test (avg * 3.267)
Std. dev. (repeatability)
6s (or axis capability)
% of Tolerance
Specified pos.
Difference
Machine Number:
Checked by:
Date:
Mach. Name:
Controller:
Unit/Cell:
Axis:
Direction:
Tolerance req.:
1. Warm up the machine
2. Select an axis and a direction
3. Position / affix reference block (s) on the table
4. Position / affix mag-base / indicator on head or table
5. Move head out to a distance beyond typical work zone
0 A B C
6. "Zero out" indicator and controller ----------------------------->
|___|___|___|
7. Move head out to a distance beyond work zone again
8. Bring head up to indicator until controller reads zero
9. Record indicator reading
10. Repeat step 9 for the next 9 readings
11. Validate initial zero indicator
12. Perform test on all axes for minus and plus directions
NB NB Indicator needle should be at 10 to 15 degrees to face to be inspected.
Indicator rod should be less than 3 inches
CAPABILITY ANALYSIS
<====
Max:
25%
<====
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?
5
(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?
3
5. Is machine firmly seated?
3
1. Dirt, dust, excess oil, rubber chips, foreign objects, damage:
5
(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?
5
4. Any indicator lamps out?
(3)
LUBRICATION
(4)
5Ss AROUND THE
MACHINE
(5)
STATUS OF
ACTIVITIES
3
1. Does oil reach sliding parts?
10
2. Is there the right amount of oil in (1)lubricator? (2) oil tank?
5
3. Do oil holes have caps ? (1) lubricator (2) oil tank
3
4. Are oil supply pipes clean, with no leaks or seepage?
5
1. Tools, instruments in assigned places ? None missing, damaged?
3
2. Are all name plates and labels clean and clearly visible?
1
3. Are covers and safety shields free of dirt, dust, fog ?
1
4. Are wires and pipes clean and clearly visible?
1
5. Any dirt, dust around machine? Dust from top of machine?
1
6. Any parts, trash, cigarette butts, plastic bags on floor ?
1
7. Any extraneous items or outdated posted matter?
1
8. Are good parts, rejects and scrap material clearly separated?
1
1. Are Kaizen examples, goals and results clearly posted on activities board?
5
2. Do plans address problem causes, cleaning difficulties ?
5
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 ?
1
Have the contaminating sources such as dust, dirt, oil, splashes, chips and others been
identified and presented on the board ?
5
2
Did we take corrective measures to resolve the sources of dust, dirt, oil, splashes
and chips, etc.?
5
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
2
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?
5
3
Is the nature of the improvements implemented/planned to simplify and
shorten the cleaning time ?
5
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 ?
1
Have the corrective actions been made for each abnormality identified at the
initial cleaning ?
ACCESS
IMPROVEMENT
(4)
ACTIVITIES
MANAGEMENT
10
1
5
5
5
5
10
5
5
5
(5)
INITIAL
CLEANING
FOLLOW-UP
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
9
9
8
8
7
7
6
6
5
5
4
4
3
3
2
2
1
1
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
D
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
Equipment:
TPM Tag No.
CONTAMINATION
SOURCE
Location:
Date:
HARD-TO-REACH
AREA
TPM IMPROVEMENT SHEET
RAISED BY:
__________________________________________
PROMISED BY:
RESPONDENT: __________________________________________
LAYOUT
__________________
DELIVERED ON: __________________
PROBLEM:
IMPROVEMENT:
Attach to the requests for service
TPM
D ate of Insp’n
IN S P E C T IO N T A G
N o.:
TPM
D ate of Insp’n
Inspector
IN S P E C T IO N T A G
N o.:
TPM
D ate of Insp’n
Inspector
IN S P E C T IO N T A G
N o.:
TPM
D ate of Insp’n
Inspector
M achine N am e & N um ber
M achine N am e & N um ber
M achine N am e & N um ber
D escription of M alfunction
D escription of M alfunction
D escription of M alfunction
D escription of M alfunction
C orrective A ction
C orrective A ction
C orrective A ction
C orrective A ction
TPM
D ate of Insp’n
C om pleted
(tick)
P erson R esponsible
IN S P E C T IO N T A G
N o.:
P lanned D ate
of A ction
TPM
D ate of Insp’n
Inspector
C om pleted
(tick)
P erson R esponsible
IN S P E C T IO N T A G
N o.:
P lanned D ate
of A ction
TPM
D ate of Insp’n
Inspector
C om pleted
(tick)
P erson R esponsible
IN S P E C T IO N T A G
N o.:
P lanned D ate
of A ction
M achine N am e & N um ber
M achine N am e & N um ber
M achine N am e & N um ber
D escription of M alfunction
D escription of M alfunction
D escription of M alfunction
D escription of M alfunction
C orrective A ction
C orrective A ction
C orrective A ction
C orrective A ction
P erson R esponsible
C om pleted
(tick)
P lanned D ate
of A ction
P erson R esponsible
C om pleted
(tick)
P lanned D ate
of A ction
P erson R esponsible
C om pleted
(tick)
P lanned D ate
of A ction
IN S P E C T IO N T A G
N o.:
Inspector
M achine N am e & N um ber
P lanned D ate
of A ction
C om pleted
(tick)
P erson R esponsible
TPM
D ate of Insp’n
Inspector
N o.:
Inspector
M achine N am e & N um ber
P lanned D ate
of A ction
IN S P E C T IO N T A G
P erson R esponsible
C om pleted
(tick)
TPM
INSPECTION TAG
No.:
TPM
INSPECTION TAG
No.:
TPM
INSPECTION TAG
No.:
TPM
Date of Insp’n Inspector
Date of Insp’n Inspector
Date of Insp’n Inspector
Date of Insp’n 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 Insp’n Inspector
Date of Insp’n Inspector
Date of Insp’n 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 Insp’n Inspector
Planned Date Person Responsible
of Action
INSPECTION TAG
Planned Date Person Responsible
of Action
INSPECTION TAG
No.:
Completed
(tick)