TPM Excellence Awards : Award for TPM Excellence Self-Checklist
Classification

1[Required]Basicrequirements
for TPM

Questions
Question

Guide
Guide

1 point

Evaluation criteria/points
2 points
3 points

4 points

5 points

All legal requirements arerecognized and regularly
assessed for compliance.

Standards that are stricter
than the legal
requirements are
established andmaintained.

There is compliance with All legal requirements are
There is no recognition ofsome legal requirements recognized, but some areapplicable legal(less than 50%
not met (50% or more
requirements.
compliance overall).
compliance overall).

- This refers to the top-level
policies of applicant companies or
1-2
plants.
Have clear top-level policies been - There is a need to confirm
established?
whether "Policy" contents areachieved through TPM
deployment.

Clear top-level policies
have been established
Although top-level policies Although top-level policies
Top-level policies have
Deployed goals are being
andNo top-level policies have have been established,
have been established,
been deployed asassessed and reviewed
disseminated/deployed
been established.
only the management are only employees are aware
policies/goals for all staff
as well.
to all staff at plants,
aware of them.
of them.
at plants.
including to nonemployees.

- There is a system to promote
activities based on theparticipation of all staff at plants.
1-3- Establish a business organization
Has a promotion system for TPM
that has overlapping smaller
been established?
groups that can directly promote
TPM to enable effective
promotion.

2-1 [Required]
At how many pillars* is it being
implemented?

2
Status of TPM
promotion

3-1
Are losses recognized?

None have been
established.

- A master plan is the timeline of
the basic TPM plan. It should be
used as a standard for activities at No master plan has been
all pillars, and as a guide whenestablished.
developing promotion plans foreach pillar.

- Award for TPM Excellence
require a minimum of six pillars:
Focused Improvement (FI),Autonomous Maintenance (AM),
Planned Maintenance (PM),- There are eight pillars, namely
Quality Maintenance (QM),
Focused Improvement (FI),
Education and Training (ET), andAutonomous Maintenance (AM),
Safety, Health, and Environment
Planned Maintenance (PM),(SHE). Early Management (EM)
Quality Maintenance (QM),
and Improvement of the
Education and Training (ET),administrative and indirect
Safety, Health, and Environment
departments(=Office(SHE), Early Management (EM),iImprovement; OI) may be
and Improvement of the
excluded from assessments if theadministrative and indirectplant does not have suchdepartments(=Office
functions.
iImprovement; OI).
- Even if actual activities are notconfigured as pillars, if activities
can be shown to have attributes ofpillars, they can be submitted for
judging.

Only the 5Ss are
implemented.

- Targets for results of activities
are called KPIs (Key Performance
Indicators), and targets forachievements are called KAIs
(Key Activity Indicators).
- Examples:
KPIs: OEE, number of failures,
percentage of defects, number ofNone have beenminor stoppages, number of
established.
accidents that cause loss time,etc.
KAIs: Number of improvements,
activity hours, number ofmalfunctions, number of OPL
sheets, number of near-missincidents, number of improvement
proposals, etc.

2-2
Have targets (KPIs, KAIs*) been
established?

4
Autonomous
Maintenance0 points- Applicable laws and regulations
are based on the country/region ofyour work location.
1-1- International certifications may
Are applicable legal requirements
be used in place of laws andbeing complied with at work?
regulations. In this case, enter
details about the certification in thegeneral overview.

1-4- There is a need to confirm
Has a master plan* for TPM
whether the plant master plan is
promotion been established for the consistent with promotion plans at
entire plant?
each pillar.

3
Focused
Improvement

Terminology- Loss-cost matrix is a table- These are to be based on the 16 comparing losses and cost. It finds
major losses that hinder
where losses are in on-site cost
None are recognized.
structures and identifies losses
productivity.
that have the greatest impact.

All legal requirements
are recognized andcomplied with.

Promotion systems foreach pillar have been
established under a TPM
promotion supervisor.

The TPM promotion
The TPM promotion
supervisor is also the(Along with the criteria
supervisor, managers,
All staff at plants
supervisor (manager) of for 2 points) There is aand front-line employees
participate in and promote
the plant, under which TPM promotion office atare all functioning within
TPM.
promotion systems for which regular meetings
the established promotion
each pillar have beenfor each pillar are held.
system.
established.

There is a master plan,but details are notspecified.

The promotion plan of
There is a master plan,
The master plan is the
The master plan iseach pillar is being
but it has not beenstandard that is being
deployed towards eachthoroughly implemented
deployed for each pillar's deployed for promotion pillar, and works together based on the master plan,
promotion plan.
plans in each pillar.
with each other.
and it is possible toconfirm this.

Only AM is implemented.

FI, AM, and PM are
implemented.

Although targets havebeen established, there
Targets (KPIs, KAIs) arehave been no analyses of set based on information
losses that would act as such as loss analysis.
the basis for targets.

6 pillars are
implemented (FI, AM,
PM, QM, ET, SHE).

Eight pillars are
implemented.

(Along with the criteria for(Along with the criteria for2 points) Measures andIt has been confirmed that
4 points) It also
actions are being taken to
KPI and KAI performance
contributes toaddress the difference
has contributed to costmanagement goals at the
between KPI and KAI
reductions.
plant.
targets and actual
performance.

Confirmation of theConversion of losses into
Definitions appropriate for
Measurements of losses
relationship between loss monetary values havethe target plant haveare being made based on
and cost are being made been made using the
been made for the 16
defined losses.
with the loss-cost matrix*. loss-cost matrix.
major losses

None are being made.

Improvements are being
made as needed.

Improvements are being
systematically made andtheir progress is being
documented.

- Showing what methods were3-3
Are improvement methods being used for improvements isused?
recommended for judging.

No

Pareto charts, statistical
tables, distribution
maps/scatter diagrams,
etc. are being used.

(Along with the criteria for
Measures against loss,(Along with the criteria for2 points) Practicalsuch as PM analysis
1 point) 4M analysis, whymethods such as Single
along with On-Site
why analysis, cause-andMinute Exchange of Die
Improvement (Karakuri
effect diagrams, etc. are(SMED) are being
Kaizen), are being taken.
being used.
implemented.

4-1 [Required]- Progress at the time of
To what extent have autonomous application
maintenance activities progressed - Base information on the numberin the seven steps* of the JIPM of applicable pieces of equipment
set when TPM was deployed.
Standards?

Completed Step 1

Completed Step 2

Completed Step 3

Currently progressing
with Step 4- Autonomous maintenance should
be conducted in steps.
- Conduct diagnosis at each stage
before going to the next one.
4-2
What activities are conducted for - Attaching/detaching tags,
autonomous maintenance?
Cleaning (C), Inspection (I),
Lubrication (L), shortening times,
visual management, inspection
skill training, etc.

Identification of
Measures against
malfunctions andattachment/detachment of sources and difficult
F(Efu)-tags, organization areas are being
implemented.
of the workplace arebeing implemented.

Cleaning (C), Inspection(I), and Lubrication (L)work are being reviewed
and standardized.

Training for workers
Overall inspection for
related to overall
inspections along with
75% or more of target
assessment of inspection equipment has alreadybeen completed.
skills are being
conducted.

3-2- Making improvements with CAPAre improvements being made? Do based on loss analysis.

4-3
Are activity boards, one-point
lessons (OPL), and meetings*
being applied effectively?

- These are known as the threeessentials for TPM*, and theirNot being applied.
application is encouraged as tools
to revitalize work sites

Further implementation(Other pillars in addition to
the 8 pillars are
implemented.)

Applied in some AM
circles.

Improvement plans are
created/implemented
based on the results ofloss analysis.

Activity boards areapplied for all AM circles,
Of activity boards, oneand effective regularpoint lessons, andmeetings are being held.
meetings, two are applied
One-point lessons arefor all AM circles.
being appropriately
managed.

Improvements are being
deployed horizontally.

75% or more target
facilities have completed
Step 4.

There are multiple
examples of zero loss
cases.

Methods and tools suchas FMEA to avoid risks(prevention) are being
used.

Completed Step 4

Preventive maintenancefor equipment and quality
have been incorporated.

Results of activity boards, One-point lessons andone-point lessons, andactivity statuses aremeeting results are
created into databases
shared with otherand applied to activities
workplaces.
throughout the company.

Self-grading

Classification

5
PlannedMaintenance

Questions
Question

Guide
Guide

1 point

Evaluation criteria/points
2 points
3 points

4 points

5 points

Identification of failurecauses along withimprovement measures
have been horizontallydeployed to relevant
facilities.

Activities that are plantwide extensions of MTBF
and contribute toshortening MTTR are
being conducted.

5-1
Are the number of failures, MTBF,
and MTTR recognized andimprovement implemented?

- Select appropriate maintenancemethods (such as TBM, CBM,
5-2
BM, CM) according to the
Are maintenance methods usedcriticality assessment ofrationally?
equipment and deterioration/failure
characteristics

Retroactive maintenance TBM is implemented foris conducted.
some equipment.

Criticality assessment ofequipment is conducted,
and TBM is implemented
for highly-criticalequipment.

TBM has been firmly
established and CBM is
being implemented onhighly-critical equipment.

- Implementation of management
for spare components, lubricants,
5-3
blueprints, tools, and maintenance
Are efforts being made to improve costs, etc.,
maintenance efficiency?
- Improved efficiency ofinspections/actions and extended
intervals of inspection

None are being made.

3Ss are being
implemented for sparecomponents, lubricants,
etc.

There is a designatedsupervisor assigned for
implementation as a
Planned Maintenanceinitiative.

There is a system built
Education and training isand applied for managing conducted forspare components,
maintenance staff, andlubricants, blueprints, and maintenance costs aretools.
being managed.

6-1
Are occurrences of defects
recognized? (What efforts arebeing made to prevent defects?)

Not taking measures.

Defects are categorized
Recognized as outflow
by phenomenon, andand in-process defects incountermeasures aredata form.
being implemented.

Work conditions toprevent defects are
established andmaintained.

Equipment improvements
Activities that exceed thethat prevent recurrences
criteria for 4 points areof defects are being
being conducted.
implemented.

6-2
What measures are taken against
individual defects?

None are being taken.

Emergency measures are Causes of defects aretaken after defects occur. pursued and eliminated.

True causes of defects
are pursued to prevent
recurrences.

Standards are revised
Consistent measures are
and training conducted to being maintained to attainprevent recurrences.
zero defects.

6-3
Is the production of good products
being managed well?

- The QA matrix displays therelationship between quality failuremode and production processes ina matrix format.
- The QM matrix displays the 3M
conditions necessary to guarantee
good products per production
No management has
process in a matrix format.
- The Q component is something been implemented.
to be displayed in order for
operators to confirm on-site/inperson that it is an important
target for management as acondition for good products.
- Q components may also becalled Q points.

7-1
Is there a training program forworkers?

8
Safety, Health,andEnvironment

0 points

Maintenance informationsuch as MTBF and MTTR
The number of failures
is being managed.
Causes of failures are
The number of failuresand downtime hours are Furthermore, failures are identified andand equipment downtime
recognized and recorded categorized andimprovements areare not recognized.
as daily reports.
measures to prevent
implemented.
recurrences are
implemented.

6
Quality
Maintenance7
Education andTraining

Terminology

7-2
Are efforts being made to build
capabilities (skills)?

There is only training for
new workers.

- The Skills Matrix categorizes
necessary expertise and skills,
and assesses each individual'sNone are being made.
skills in stages, and displays this ina matrix.

Quality standards havebeen established.

QA matrix* is being used
to clarify the relationship QM matrix* is being used
to maintain conditions for
between failure modes
good products.
and production
processes.

Safety and skill training
are conducted.

Skill training using
educational materials(Maintenance Dojo)
based on OPL andpractical experience isconducted.

Preventive maintenance Equipment maintenancehas been established with systems have been
periodic/predictive
established and is inmaintenance.
operation.

There is a system in place
for maintenance (and isestablished as amechanism).

Q component*
configurations are made Activities that exceed theto manage conditions for criteria for 4 points aregood products on a daily being conducted.
basis.

Technical training such as Training related tofor equipment principles is improvement methods,
conducted.
etc. is conducted.

Training related to
improvement skills suchas Karakuri Mechanisms
is conducted.

Training is conducted
OJT is conducted to pass Skills are visualized in thebased on the Skills
on skills.
Skills Matrix*.
Matrix.

There is a system toMulti-skill development isencourage acquisition of
being conducted, or there
public qualifications, oris an in-housethere is a system toqualification system.
commend qualifications.
(Along with the criteria forEnvironmental
3 points) An environment
developments thatthat allows staff to receive
exceed the criteria for 4
correspondence
points has been
education, e-learning, etc.
implemented.
is available.
Workplace environment
improvements are being
implemented, such asthat for noise.

- Environments for selfdevelopment generally are those
7-3
such as providing books,
Has an environment been created correspondence education,
for self-development?
support such as e-learning, orproviding physical space foreducation such as a dojo.

None have been
established.

There are sufficient
Efforts are being made to Some books and learning
books/learning materials
create an environment for materials have been
available to promote
self-development.
prepared.
TPM.

8-1
Is safety and health management
being implemented?

Yes, to the level of legal
standards.

Activities such as risk
Measures are being taken
Measures are being taken analysis are being
against occupational
against near misses and undertaken to prevent
accidents that havenoted unsafe areas.
incidents andoccurred.
occupational accidents.

8-2
Are safety measures being
implemented?

Safety patrols and asystem for reporting
unsafe areas areavailable.

Safety training is being
conducted.

Measures to eliminate
Protective measures such Measures to eliminate
unsafe areas in work
as safety fences, covers, unsafe areas (Poke Yoke,
areas outside that ofand signage are
fail-safe) areregular work are being
implemented.
implemented.
implemented.

Activities that exceed thecriteria for 4 points arebeing conducted.

8-3
Is the environment being
managed?

Yes, to the level of legal
standards.

Reduction of waste, etc.
is being implemented.

Energy and resource
Daily management of
The 3Rs (Reduce, Reuse,conservation based onenergy loss is being
Recycle) aredata such as energy loss
implemented.
implemented.
is being implemented.

Voluntary targets are
configured andmanagement towardachieving targets is being
implemented.

Activities that exceed thecriteria for 4 points arebeing conducted.

Self-grading

Classification

Questions
Question

9-1
Is there a system for installing
equipment?

9
EarlyManagement*This is not arequiredelement for
judging.

Guide
Guide

Terminology- For the Early Management
category of Award for TPM
Excellence, "Early Management of
products" is not a required activity.
However, if activities for the "EarlyManagement of products" arebeing conducted, they will be
included with the other criteria tobe scored. (There will be no points
subtracted for this if it does notmeet the standard criteria). In thiscase, please change the items for
judging from "equipment" to"products" for questions 9-1 to 9-3.

- TPM efforts are requested for
9-2
early management for equipment.
Has a system for equipment early In other words, specific efforts to - KPI: Key Performance Indicator
management been established, reflect the concept of maintenance - KAI: Key Activity Indicatorand have clear targets been set? prevention (MP) on equipment
should be implemented.

MP design: Maintenanceprevention design. Past
experiences and applicable newtechnologies are collected as MP
information to be used for thedesign of new equipment

9-3
Is MP design considered whenintroducing equipment?

10-1
Are losses in administrative andindirect
departments clarified and have
improvements produced results?

10
Improvement- It is recommended to separateof theissues to improve efficiency in
Administrative
your department from issues to be
10-2
and Indirect
resolved across departments.
Departments Is work evolving to become more("Autonomous Maintenance" andefficient?
"Focused Improvement" for the*This is not aadministrative and indirect
requireddepartments)
element for
judging.
10-3- It is important to clarify what
Are there any efforts being madeexpertise and skills are necessary
to improve staff work performanceto perform duties.
capabilities?

0 points

1 point

There is almost no
consideration of this.
(Installation of equipment
is led by headquarters
with no involvement byplants.)Although we supervise
installation of equipment
as a plant, we are not
involved in deliberations
on its specifications.

We are not able to, or do
not get involved with
The only goal is to meet
specifications, operations,the budget.
etc., during equipment
installation.

Evaluation criteria/points
2 points
3 points

We offer design reviews,
Information on safety,
etc. at the equipment
operation, andplanning stage, which
maintenance are provided
enables us to incorporate
as MP information forrequirements necessary
equipment specifications.
for the plant.

Target values for"shortening development
periods" and "verticallaunch" have been
established as KPIs.

4 points

5 points

During the productplanning period,
Activities that exceed theconsideration is given to criteria for 4 points are
systems that will maintain being conducted.
good product conditions.

Development period
management has been
The early management
appropriately
system for equipment is
implemented and targets
used for process andhave been attained. Or,
equipment design duringmalfunctions were
new product planning.
uncovered before launch,enabling vertical launch.

Assessments ofenvironmental impacts
are conducted andpassed when new
equipment is developed.

MP-designed equipment
goes through on-site
assessments for
effectiveness andadequacy after
installation.

Activities that exceed thecriteria for 4 points arebeing conducted.
(Equipment design thattakes into account quality
assurance, theenvironment, installation
space, etc., based on MP
design)

Past information on
A system to used
MP design is conducted
It is rarely considered.
failures, safety, operation, collected information as
using MP information.
(Installation of equipment
maintenance, etc., is
MP information has been
Furthermore, it is also
is led by headquarters
collected but notestablished, but this is notreflected in the checklist
with no involvement byrecognized as MP
applied to newat design reviews.
plants.)information.
equipment.

New measures foradministrative and indirect Organizational reform foradministrative and indirect
departments loss, withdepartments is being
the supply chain inconsideration, are being conducted (such as DX).
implemented.

Losses are not clarified.

Although losses arerecognized, no activities
for improvement are
being made.

Losses are defined andindicators configured.

Nothing is being done.

3S (Sort, Set in order,
Shine) activities for the
workplace environmentare being implemented.

Document filing, supplies, Effective tools for improve
Reform for indirect
and digital data
work efficiency are used, Work improvements havedepartments (such as
successfully shortening
been started, including at
management are beingDX) are being conducted
properly implemented to work hours and work lead suppliers, with success.
with success.
improve work efficiency. times.

There is no training plan,
Planned training is being
Necessary skill sets haveand training is conductedconducted through OJT
been identified.
on an ad hoc basis.
and Off-JT.

Themes for improvement
are noted for losses,
which are applied to work
improvement activities.

Self-grading

Skill assessments arebeing applied to enablestaff to attain targetedskills.

Reforms that will improveIndirect work is being
the work efficiency forstreamlined with multiindirect departments are
skilling, work leveling, etc.
being implemented.

3 points

4 points

Reference (The following items are not subject to judgment by self-grading. However, in the Assessment, the results of TPM will be included and judged comprehensively.)Classification

Question

Guide

BM stands for benchmark. It is
often a starting point for activities
covered by Award for TPM
Excellence.

Have there been reductions in thenumber of accidents that cause
loss time?

Has productivity improved?

[These are notsubject tojudgment by
self-grading.]
TPM results

Terminology- Examples of assessment
indicators (OEE, OLE, OPE, etc.)

0 points

1 point
There have been morethan three incidents/year
There have been morein the last year, or there
than six incidents/year inhas been an
the last year, or there has
approximately 10%
been no change.
reduction compared to
the BM.

No improvement, or it isgetting worse.

Has the number of failuresdecreased?

No decrease, or there
have been increases.

Has the number of defects
decreased?

No decrease, or there
have been increases.

- Proposals for improvement are
not limited to TPM activities, andthe proposals themselves are
something to be encouraged andHas the number of proposals forrespected.
improvement* increased?
- The number of proposals for
improvement include proposals
that have been implemented aswell.

- Proposals for improvement also
include the following:- Proposals related to the 16 major
losses- Proposals related to measures
0 proposals/person per
taken against the origins ofmonthproblems- Proposals for levels of tagging
faults (malfunctions)- Proposals related to safety andthe environment

2 points

There have been two
There has been one
incidents/year or less inincident/year in the last
the last year, or there has year, or there has been
been an approximately
an approximately 50%
30% reduction compared reduction compared toto the BM.
the BM.

5 points

There have been zero
There have been zeroincidents in the last two
incidents in the last year.
years.

There has been an
There has been an
There has been an
There has been an
approximately 15%
approximately 15%
Better results than theapproximately 5%
approximately 10%
improvement compared to improvement compared to criteria for 4 points have
improvement compared to improvement compared to
the BM, or 75% OEE has the BM, or 85% OEE has been attained.
the BM.
the BM.
been attained.
been attained.
There has been an
There has been an
There has been an
It has decreased to less It has decreased to lessapproximately 10%
approximately 30%
approximately 50% orthan 20% (1/5) compared than 10% (1/10)
decrease compared todecreased compared to more decrease comparedto the BM.
compared to the BM.
the BM.
the BM.
to the BM.
There has been an
There has been an
There has been an
There has been an
It has decreased more
approximately 10%
approximately 20%
approximately 30% orapproximately 50% orthan the criteria for 4
decrease compared todecreased compared to more decrease compared more decrease comparedpoints.
the BM.
the BM.
to the BM.
to the BM.

1 proposal/person permonth

1 to 2 proposals/person
per month

2 to 3 proposals/person
per month

3 to 5 proposals/person
per month

5 proposals/person permonth or more

Self-grading