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TotalProductiveMaintenance

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JIPM - TPM Sample FormatSample Formats for the12 Steps of TPM

Compiled by Japan Institute of Plant Maintenance

Japan Institute of Plant Maintenance (www.jipm.or.jp)

How to Use This ManualThis manual consists of 22 chapters, as shown in Table 1. On the first page of each chapter, there is an outline table of contents of work flow and the forms used to perform those operations. (Figure 1) The numbers in the upper right hand corner of the forms in the body, such as 1 1-1 (Figure 2), indicate major category as shown in Figure 1, intermediate category, and form number, respectively. In addition, the numbers in the blancket [numbers inside ( )] to the right of work flow subcategories correspond to form numbers. Using the table of contents to find necessary forms, you can copy and arrange forms to meet your needs.Table 11 2 3 4 5 6 7.1 7.2 7.3 7.4 8.1 8.2 9 10 11 12 A B C D E

Title of Each ChapterDeclaration by Top Management Introduce TPM Education and Campaign to Introduce TPM Establishment of a TPM Promotion Organization and Formal Organization Model Setting the Basic Policy and Goals of TPM Creating a TPM Master Plan TPM Kickoff and PR Kobetsu Kaizen (Individual Improvement) Jishu Hozen (Autonomous Maintenance) Keikaku Hozen (Planned Maintenance) Upgrading Operation and Maintenance Skills Initial Phase Control (Product) Initial Phase Control (Equipment) Hinshitsu Hozen (Quality Maintenance) Office TPM Safety, Health and Environment Management System Thorough Implementation and Continuous Improvement of TPM President's Diagnosis Meeting TPM PR Activities Three Jewels of Autonomous Maintenance Presentation Meeting (Circle Conference) Suggestion System

Figure 1

Example of Contents

Chapter Title (Major Category)

Figure 2

Example of Forms

TPM Sample Formt Sample Formats for the 12 Steps of TPM CONTENTS

1.

Declaration by Top Management to Introduce TPM

1-1 1-1-1 1-1-2 1-1-3 1-1-4 1-1-5 1-2 1-2-6 1-2-7 1-2-8

Understanding of TPM by Top Management in Order to Introduce TPM Notification of Pre-Study Meeting for the Introduction of TPM Announcement of Diagnosis Meeting for Top Management Plan for Top Management Tour of TPM Promotion Plants Notification of One-Day Seminar Announcement of TPM College Courses {1} Announcement of TPM College Courses {2} Schedule of TPM College Courses Declaration by Top Management to Introduce TPM TPM Introduction Plan Establishment of a Committee to Prepare for Introduction of TPM (In-company circular) TPM Declaration (Example)

2.

Education and In-company Publicity to Introduce TPM

2-1 2-1-1 2-1-2 2-1-3 2-1-4

Education to Introduce TPM TPM College In-House Course Plan TPM Dissemination Education Plan TPM Site Leaders Training Course Participants in In-company and Public Seminars and Plant Tours

2-2 Publicity 2-2-5 Poster and Slogan (In-company notice) 2-2-6 Design of TPM Emblem (In-company notice) 2-2-7 Example of In-company Newsletter (the monthly Diesel )

3. Establishment of a TPM Promotion Organization and Pilot Model

3-1 3-1-1 3-1-2 3-1-3 3-1-4 3-1-5 3-1-6 3-1-7 3-1-8

3-1-9 3-1-10 3-1-11

Company -Wide TPM Promotion Organization Company-Wide TPM Promotion Organization Plant TPM Promotion Organization Sub-committee Organization Purpose and Main Activities of the 8 Pillars of TPM / Table of Roles of Each Sub-committee Meeting Table of Members of Sub-committee Committees Committee Activity Plan / Example : 5S Committee Pilot Model Team Organization Chart Pilot Model Registration {1} Jishu Hozen (Autonomous Maintenance) {2} Kobetsu Kaizen (Individual Improvement) TPM Department Promotion Organization Chart TPM Circle Members Registration / Notification of Change List of Meetings

4.

Setting the Basic Policy and Goals of TPM

4-1 4-1-1 4-1-2 4-2 4-2-3 4-2-4 4-2-5 4-3 4-3-6 4-4 4-4-7 4-4-8 4-4-9 4-5 4-5-10

Setting Company-Wide Basic Policy and Goals Table of Members Organized to Ensure Common Understanding Implementation and Diagnosis of Policy Determination of the Basic Policy and Goals of the Plant Background to and Purpose of Introducing TPM (Plant) Policy and Goals of TPM (Plant) {1} {2} The Shift from DPM Activity to ZPM Activity Determination of Activity Slogan Solicitation Requirements for TPM Activities Slogan Creation of Activity Priorities and Activity Policy Implementation Diagram Activity Policy Implementation Diagram Goals Implementation Diagram Critical Tasks and Target Values by Activity Organizing Basic Approaches to Setting Targets Basic Approaches to Setting Targets

5. TPM Master Plan

5-1 5-1-1 5-1-2 5-1-3 5-1-4

Basic Company-Wide TPM Policy Department Activity Plan Pilot Line Activities Plan Sub-committee Meeting Activity Plan Master Plan

6.

TPM Kickoff and PR

6-1 6-1-1 6-1-2 6-1-3 6-1-4 6-1-5 6-1-6 6-1-7 6-2 6-2-8 6-2-9 6-2-10 6-2-11

Kickoff Preparation Schedule up until Kickoff Meeting Event Plan Detailed Schedule up until Kickoff Meeting Venue Layout Diagram for the Kickoff Meeting Supplies List Division of Roles for Kickoff Meeting Announcement of TPM Kickoff Meeting Kickoff Conference Manual for the Kickoff Meeting Kickoff Conference Program Conference Slogan (Example) Publish in Company Newsletter

7.1

Kobetsu Kaizen (Individual Improvement)

7.1-1 Ten Step Implementation of Kobetsu Kaizen 7.1-1-1 Overall Equipment Efficiency (OEE) and Effective Process Duration Calculations Sheet 7.1-1-2 Man-Machine Chart 7.1-1-3 Organizing a Project Team 7.1-1-4 Definition of 16 Major Losses 7.1-1-5 Loss Analysis Checklist 7.1-1-6 Loss Analysis of XX Process 7.1-1-7 Setting Targets (List of Themes for Kobetsu Kaizen) 7.1-1-8 Setting Level Evaluation (Evaluating the Level of Overall Equipment Efficiency) 7.1-1-9 Master Plan (for Kobetsu Kaizen) 7.1-1-10 Kobetsu Kaizen Planning Chart

7.1-1-11 7.1-1-12 7.1-1-13 7.1-1-14 7.1-1-15 7.1-1-16 7.1-1-17 7.1-1-18 7.1-1-19 7.1-1-20 7.1-1-21 7.1-1-22 7.1-1-23 7.1-1-24 7.1-1-25 7.1-1-26 7.1-1-27 7.1-1-28

Example of Form for Why-Why Analysis 5W Image Analysis Sheet {1} Understanding of Overall Status {2} 5W Image Analysis Step-by-step Implementation of PM Analysis Examples of PM Analysis Steps for Reducing Setup and Adjustment Losses Steps for Reducing Cutting Blade Change Losses Steps for Reducing Start-Up Losses Steps for Reducing Minor Stoppage Losses Steps for Reducing Speed Losses Steps for Reducing Defect Losses Improvement Sheet (TPM Improvement Sheet and MP Information Sheet) Results Graph Example QC Process Chart Standard Documents {1} Work Standards Sheet {2} PM Standards Sheet Kobestu Kaizen (Individual Improvement) Results Table Theme Resolution Summary Format Highly Successful Improvement Horizontal Replication Map (Kobetsu Kaizen)

7.2

Jishu Hozen (Autonomous Maintenance)

7.2-1 Jishu Hozen Implementation Steps 7.2-1-1 Example of Steps to Implement Jishu Hozen 7.2-1-2 Implementation Table of 7 Steps for the Process Industry 7.2-1-3 Implementation Table of 7 Steps for the Assembly Division 7.2-1-4 Implementation Table of 4 Steps for the Warehouse and Logistics Divisions 7.2-2 Creation of a Promotion Plan for Jishu Hozen 7.2-2-5 Jishu Hozen Master Plan 7.2-2-6 Education Schedule {1} Jishu Hozen Education Curriculum {2} Jishu Hozen Introduction Education Schedule 7.2-2-7 Model Equipment Selection Standards 7.2-2-8 List of Jishu Hozen Registered Machines (Machines on which the Jishu Hozen Step is to be Implemented) 7.2-2-9 Board for Displaying Registered Machines and Managing Progress of Steps 7.2-3 Jishu Hozen Diagnosis System 7.2-3-10 Jishu Hozen Diagnosis Flow Chart 7.2-3-11 Step Diagnosis Sheet (Step 1) 7.2-3-12 Application Form for Top Executive Diagnosis 7.2-3-13 Passed Diagnosis Seal

7.2-4 Step 0: Preparation 7.2-4-1 Preparation for Step 0 7.2-4-2 Educational Materials 7.2-4-3 Cleaning and Safety Education {1} Understanding TPM Jishu Hozen Safety and Health {2} One-Point Lesson 7.2-4-4 Relationship Between Forced Deterioration and Losses 7.2-4-5 Structural Diagram of Mechanism {1} Creation of Structural Diagram of Mechanism {2} Structural Diagram of Cylindrical Grinder 7.2-4-6 Educational Materials for Cleaning, Oiling, and Retightening Work (One-Point Lesson) {1} Oiling {2} Retightening 7.2-5 Step 1: Initial Cleaning (Cleaning and Inspection) 7.2-5-1 Procedure to Implement Step 1 7.2-5-2 Activity Plan for Step 1 7.2-5-3 Map of Cleaning Area 7.2-5-4 Cleaning Procedure 7.2-5-5 Map of Oiling Locations 7.2.5-6 Map of Retightening Locations 7.2-5-7 Example of Tags and Usage 7.2-5-8 Planning Chart for Improving Slight Defects 7.2-5-9 Classification Table of Identified Slight Defects 7.2-5-10 Know-Why Sheet 7.2-5-11 Table of Identified Difficult-to-Access Locations for Cleaning, Inspection and Oiling 7.2-5-12 Improvement Sheet 7.2-5-13 Improvement Location Label 7.2-5-14 Tag Removal Tree 7.2-5-15 Improvement Effectiveness {1} Changes in Activity Time {2} Changes in the Number of Tags Attached {3} Changes in the Number of Know-Why Sheets Issued 7.2-5-16 Step 1 Diagnosis Sheet 7.2-6 Step 2 : Countermeasures for Generating Sources and Difficult-toAccess Locations 7.2-6-1 Procedure for Implementing Step 2 7.2-6-2 Planning Chart for Step 2 Activities 7.2-6-3 Map of Generating Sources (What, Where and How Much) 7.2-6-4 Map of Difficult-to-Access Locations (What, Where and How Much) 7.2-6-5 Why-Why Analysis Sheet 7.2-6-6 Schedule of Countermeasures, and Improvements and Restoration 7.2-6-7 Countermeasures for Difficult-to-Access Cleaning and Inspection Locations 7.2-6-8 Countermeasure for Generating Sources 7.2-6-9 Step 2 Diagnosis Sheet

7.2-7 Step 3: Tentative Jishu Hozen Standard 7.2-7-1 Procedure for Implementing Step 3 7.2-7-2 Planning for Step 3 Activities 7.2-7-3 Tentative Cleaning and Inspection

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