Revision of TPM Excellence Awards

Japan Institute of Plant Maintenance
TPM Awards OfficeThis revision is effective from 2024 TPM Excellence Awards.
However, it is possible to be assessed for the three-year period from FY2024 to FY2026 by applying requirements andchecklists prior to the revision.

CONTENTS
1.

Purpose of revision

2.

Major changes due to revision3.

Description of changes
1) Classification/structure of award categories
2) Requirements
3) Self-checklist4) Assessment method

4.

Effective Date of the revision１．Purpose of revision
As the business environment changes day by day, the organizational structure ofmanufacturing sites is diversifying, and technological innovation has brought about majorchanges in various activities, including equipment and improvements. TPM has continued
to evolve in this environment, and is currently being introduced by many companiesglobally.
TPM Excellence Awards has been revised in line with changes in the corporateenvironment. The latest revision is also made with an awareness of the need to adapt to"organizations specializing in production functions" and "expansion (mixing) of activities
other than TPM ". In addition to making it easier to evaluate activities mainly atproduction sites, we believe that this will help manufacturers to maintain and continue
TPM activities, or to further expand and step up their TPM activities.

２．Major changes due to revision -１
 In TPM, it is essential to maintain and continue activities. However, there are somecompanies that are satisfied with award and stop TPM activities themselves. The TPM
Excellence Awards allows to challenge for the same award category again and again. We
have clearly institutionalized this. Please use the award system not only to evolve andexpand your activities, but also as a mechanism to maintain and continue them. 【Refer３．１）Classification/structure of award categories】
 This revision will make it easier for organizations that specialize in production functions, i.e.,
those that do not have development or administrative functions, to use the TPM ExcellenceAwards. Although TPM activities are based on the eight pillars, it is possible fororganizations, including higher-categories, to be assessed without the two pillars of EarlyManagement and Improvement of the administrative and indirect departments, dependingon the organization and the form of the activity. 【Refer ３．２）Requirements】

２． Major changes due to revision -２
 For first-time applicants, it may be difficult to judge whether they have achieved enoughto challenge for the TPM Excellence Awards. JIPM has Pre-Assessment system for thisproblem. However, in order to allow companies to make certain judgments and toconfirm that they have the basics of TPM activities in place, we prepare a “Self-Checklist”
for the first category of TPM Excellence Awards.

【Refer ３．３）Self-checklist】

 TPM activities are based on Genchi Genbutsu (actual place and thing), and the TPM
Excellence Awards assessments are also conducted by visiting the plants. However, there
are risks and burdens associated with flights and travels. For this reason, we havedecided to allow online assessment for the 2nd Stage Assessment of the TPM ExcellenceAwards if certain conditions are met. 【Refer３．４）Assessment method】

３．Description of changes

１）Classification/structure of award categories -1

The categories of the TPM Excellence Awards are changed as shown in the table below.
A graphical representation of the old and new category classifications and structure canbe found on the next page.
OldNew→

Category A" and "Category B" are integrated.
The first award to be challenged will be the“Award for TPM Excellence".

After receiving Category A or Category B, "youmust receive Award for Excellence in Consistent
TPM Commitment to challenge for Special
Award for TPM Achievement."→

After receiving Award for TPM Excellence, "it ispossible to challenge for Special Award for
TPM Achievement without receiving Award forExcellence in Consistent TPM Commitment".

It was not clearly indicated that "the same award
category could be accepted multiple times."→

Newly established "Stages of repeatassessment".

The first award category to be challenged is"Category A" or "Category B".

３．Description of changes

１）Classification/structure of award categories -2
TPM Excellence Awards Category Structure Chart
Old structure

New structure

World ClassWDWorld Class
2yearsAdvanced Special

3yearsSilverSpecialSp
2yearsConsistent

3yearsConsistent
2yearsCategory A

Category B

GoldWD
Platinum

Advanced Special
2yearsSpecialWD

SilverCon
SilverSp
GoldConGoldSp
PlatinumCon
Platinum

Excellence★ Development Stage★ Maintain Stage３．Description of changes１）Classification/structure of award categories -Explanation

 First Step Category in the Award is the "Award for TPM Excellence"
The most significant change in category classification is that "Category A" and "Category B", thefirst step categories in the TPM Excellence Awards, will be merged to become the "Award for TPMExcellence". As described below, the minimum requirements will be six pillars for all categories.

 “Special Award for TPM Achievement” can be challenged without receiving “Awardfor Excellence in Consistent TPM Commitment”
Until now, it was necessary to have received "Award for Excellence in Consistent TPM
Commitment" to be eligible for " Special Award for TPM Achievement”. In this revision, awarded ofthe "Award for Excellence in Consistent TPM Commitment" is not a mandatory requirement.
However, assessment criteria themselves will remain the same, and Special Award for TPM
Achievement will still require that "maintenance and continuation of activities have been
established as a mechanism", which was previously checked for the " Award for Excellence inConsistent TPM Commitment ".

３．Description of changes

１）Classification/structure of award categories -Explanation
 "Maintain Stage" for repeated challenges in same category
While it has always been possible to repeat challenges all categories, "Maintain
Stage" has been newly established to clearly indicate this. We have positioned"Development Stage" as a stage in which activities are evolving and expanding inorder to achieve higher-level awards category. "Maintain Stage" is intended to be
used by companies that wish to steadily continue their activities. "Maintain Stage"
has been established for the "Award for Excellence in Consistent TPM Commitment",
the "Special Award for TPM Achievement", and the "Award for World-class TPMAchievement". From second challenge, title will change to "Silver", "Gold", or"Platinum" depending on the number of repetitions, to indicate that TPM activities
have been continued for a long period of time.

３．Description of changes

１）Classification/structure of award categories -Reference <Reference> Positioning of "Award for Excellence in Consistent TPM Commitment"and "Advanced Special Award for TPM Achievement “As described after, activities for "Special Award for TPM Achievement" are to have unique strengths,
and activities for "TPM World Class Award" are to be the world No. 1 or Only 1 company/plant. On theother hand, "Award for Excellence in Consistent TPM Commitment" is positioned as the establishmentof a foundation to maintain and continue what has been established in the “Award for TPM Excellence"and to create a unique strength for "Special Award for TPM Achievement". Similarly, "Advanced Special
Award for TPM Achievement" will have the following two objectives: to establish unique strengths
created in "Special Award for TPM Achievement" and to engage in activities aimed at becoming No. 1or Only 1 for "TPM World Class Award.
Due to this revision, "Award for Excellence in Consistent TPM Commitment" and "Advanced Special
Award for TPM Achievement" are no longer mandatory requirements to receive higher award
categories, but they can be used depending on activities that company/plant is aiming for.

３．Description of changes２）Requirements
Requirements for TPM Excellence Awards have been revised as shown in the table below.
(Only changes are noted)
Old requirements

New requirements→All categories are based on 8 pillar activities, but
Early Management and Office pillars can beexcluded from the assessment

To be eligible for Special Award for TPM
Achievement, the applicant must have received
Award for Excellence in Consistent TPM
Commitment→To be eligible for Special Award for TPM
Achievement, applicant must have received Awardfor TPM Excellence（No requirement to havereceived Award for Excellence in Consistent TPM
Commitment）

Advanced Special Award for TPM Achievement
must establish important items→

Establishment of important items is not required

All categories except Category B (5 pillars) require 8
pillar activities

In addition to the above, there are some modifications in wording３．Description of changes２）Requirements
 Pillars of Focused Improvement, Autonomous
Maintenance, Planned Maintenance, and Quality
Maintenance are directly related to reducing losses
and improving OEE in production activities, and must
be implemented.

Essential pillars for
TPM implementation

OFFICE

Early Management

SHE

E&T

Quality Maintenance

Planned Maintenance

Autonomous Maintenance

Focused Improvement

Essential pillars directly
involved in production activities

 Pillars of Education and Training, Safety, Health, andEnvironment are activities required to implement TPM.
 Pillars of Early Management and Office (Improvementof the administrative and indirect departments) may
be excluded from the assessment for the TPM
Excellence Awards, as some plants may not have thatfunction.
In practice, even if the activities of each pillar are developed
uniquely, such as being promoted under composite (or under adifferent name), JIPM may accept application if the elements ofeach activity are included and auditee can provide explanations.
However, it is preferable to consult with the TPM Awards Office inadvance (preferably at the time of consideration for challenging
assessment).

Pillars that do not have thatfunction in some plants/factories

３．Description of changes
２）Requirements -Explanation
Diagram of new requirements
Deepening and expanding
scope of activities

GlobalNo.1 or Only1

Activity Level
DeeplyAggressive

UniqueStrengths
Establish
Activities
Establish
SystemDeepening
activities without
broadening scope

WDADSpecial
Consistent
Excellence
TPM 8pillars

Maintain activity level andexpand scope

Can be 6 pillars ofonsite-based

TPM 8pillars TPM 8pillars(+α) +β+α (+β)+α︓Additional/Unique Activities+β : Strategic Activities

Axis Activity Areas（management perspective）

Widely３．Description of changes２）Requirements -Explanation
 Concept of Axis Activity Areas（Widely）
The minimum requirements for TPM Excellence Awards assessment are six
pillars of onsite-based activities. However, especially in higher categories, it isnecessary to consider expanding the scope of activities as follows, based onnature or scale of the business.
+α activities : Additional or Unique Activities
Activities mainly within or adjacent to plant/factory operations+β activities : Strategic Activities
Mainly activities involving outside plant/factory(head office functions, suppliers, etc.)

３．Description of changes２）Requirements -Explanation
 Concept of Activity Level（Deeply/Aggressive）
As TPM activities proceed, it is also necessary to further advance and evolve or
deepen the activities to date.
Award for TPM Excellence and Award for Excellence in Consistent TPM Commitment
are for the stage of establishing a system to make the activities take root andbecome a mechanism.
Special Award for TPM Achievement clarifies the company's unique strengths, andAdvanced Special Award for TPM Achievement further solidifies these strengths.
Award for World-class TPM Achievement is for that have developed their strengths
and are aiming for the position of Global No. 1 or Only 1.

３．Description of changes２）Requirements -Explanation
 Enhancement of basic activities
・Six pillars of onsite-based activities
・Early Management (Equipment)
・Office Example of ＋α activities（Additional or Unique Activities＝Activities mainly within or adjacent to plant/factoryoperations）

・ʼCost Activityʼ as a derivative activity of Focused Improvement
・ʼMold Maintenance Activityʼ as a derivative activity of Planned Maintenance・Early Management（Products）
・Safety, Health, and Environment are divided into ʻSafety and Healthʼ and ʻEnvironmentʼ

…etc.

 Example of ＋β activities（Strategic Activities＝Mainly activities involving outside plant/factory）
・Supply chain activities (related to logistics, sales, purchasing)・Information innovation activities (related to IT, Web utilization, marketing)・Smart factories (related to low-cost automation)
・Carbon neutral, Energy reduction, Environmental activities
・TPM at Vendors…etc.

 Example of Deepening activities
・7 Zero activities
・Outstanding activities …etc.

３．Description of changes
２）Requirements -Explanation
Diagram of new requirements (plots of additional/deeper activity examples)
GlobalNo.1 or Only1

Activity Level
DeeplyAggressive

UniqueStrengths

・Outstanding
activities
・7 Zero activities
・High-mix
production
・Single piece flow
・In-plant logistics

Establish
Activities
Establish
System・Sales/Customer
aproach
WD・Bench Marking
・Smart factory
・Information
innovation
ADactivities
・Carbon neutralSpecial

・Supply chain

・Karakuri Kaizen
Consistent・Machining
PointAnalysis
・Products EarlyManagement
Excellence

TPM 8pillars

Can be 6 pillars ofonsite-based

TPM 8pillars TPM 8pillars(+α) +β+α (+β)

Axis Activity Areas（management perspective）

WidelyDeepening of 8pillars(+α）
Expansion beyond 8pillars(+β)
Varies according to plant characteristics,
technological developments, etc.

３．Description of changes３）Self-checklist
 Self-checklist
In revised TPM Excellence Awards, the first award category to be challenged
is the “Award for TPM Excellence”. Self-checklist indicates the activities or
activity levels to be cleared before challenging this category, which is thefirst step in the process. It can also be used as a target for activities to beundertaken in pursuit of the award.

Whatʼs Self-checklist︖
 You can judge for yourself if you are eligible to challenge for Award for TPM Excellence.
 During the assessment, assessors will also use this list as a reference for its evaluation.

３．Description of changes３）Self-checklist
 Own judgment by self-checklist
Considering challenge for Award for TPM Excellence, applicant must answer
all of the questions on the self-checklist and meet the following two criteria.
１．All “Required items” must have a score of “3” or higher.
２．Average score of all items must be at least "2.5" at the time ofapplication.
（6 to 8 pillars depending on company declaration）
Note that even if a plant/factory meets these criteria in its own evaluation, thisdoes not guarantee that it will receive Award for TPM Excellence.

３．Description of changes３）Self-checklist -Explanation
 Positioning of Self-checklist
Self-checklist will replace existing checklist for Award for TPM Excellence and Award for
Excellence in Consistent TPM Commitment. For Special Award for TPM Achievement,
Advanced Special Award for TPM Achievement, and Award for World-class TPMAchievement, there will be no change from the previous checklist. Self-checklist isdesigned to allow a score evaluation from 0 to 5 points, depending on the progress ofthe activity. Self-checklist can be used as a guideline for self-judging whether youractivities are at a level that will allow you to challenge for Award for TPM Excellence.
Award for Excellence in Consistent TPM Commitment will also be assessed using theself-checklist, but the score for all items must not be less than score for the Award for
TPM Excellence.

３．Description of changes
４）Assessment method
 Changing assessment method
Currently, except for special cases due to the impact of Covid-19, TPM
Excellence Awards assessment is conducted in principle by an on-site
assessment by assessors visiting auditee's site. On the other hand, inconsideration of the fact that there are special circumstances, such asregions where travel is difficult or the time of year, JIPM will allow online
assessment only for 2nd Stage assessment. Assessors in charge of 1stStage Assessment and TPM Awards Office will decide whether or not toconduct the assessment online after receiving a request from the auditee todo so.

４．Effective Date of the revision2024
New system

ApplyOld system

Available

2025

2026

2027

Available

Available

NOT available

 When new system will be applied
Since new system focuses on revisions that will make it easier for auditee to use TPM
Excellence Awards, it will apply from 2024. On the other hand, for plants/factories thatwere aiming for Category B, application under the old system (5 pillars) will be accepted for
3 years from 2024 to 2026, since this revision will increase the pillars of their activities. Inprinciple, assessment for "Award for TPM Excellence" will be based on Self-checklist, but
assessment based on old checklist is also possible upon request.

TPM Awards Office

TPM Awards Office
Japan Institute of Plant MaintenanceMailtpmawards@jipm.or.jp