TPM Self-Assessment Guidebook & Tool

C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png TPM Self-Assessment Guidebook & Tool This package helps you to conduct a systematic TPM self-assessment based on the JIPM standard and identify areas for improvement. It also provides a means to establish a baseline for your organization so that you can measure its progress over time. © Operational Excellence Consulting. All rights reserved.

NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg NOTE: This is a PARTIAL PREVIEW. To download the complete presentation, please visit: https://www.oeconsulting.com.sg Objectives By the end of this self-assessment program, you will be able to: 1. Understand the TPM framework based on the JIPM standard for world-class manufacturing excellence 2. Define the TPM Criteria and Evaluation Areas 3. Describe the Point Values and Scoring Guidelines 4. Conduct a systematic TPM self-assessment and identify areas for improvement 5. Establish a baseline position so you can measure your progress over time 2 2 © Operational Excellence Consulting. All rights reserved.

Contents 1. Overview of the TPM Excellence Model 2. Criteria for TPM Excellence 3. Award Criteria Guidance Points 4. Scoring Guidelines 5. TPM Self-assessment 6. Post TPM Self-assessment 3 3 © Operational Excellence Consulting. All rights reserved.

1 Overview of the TPM Excellence Model C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png © Operational Excellence Consulting. All rights reserved.

Overview of TPM Excellence Model About JIPM • Established in 1969 • Non-profit organization • Provides services to factory/plant management, plant engineers and maintenance managers • Develops and promotes total productive maintenance (TPM) • Originator of TPM since 1971 Note: JIPM = Japan Institute of Plant Maintenance 5 5 © Operational Excellence Consulting. All rights reserved.

Overview of TPM Excellence Model Objectives of JIPM 1. Research and development in production technologies 2. Collect and disseminate information and materials about production technologies 3. Certify skills for production activities 4. Exchange information with various organizations, both in Japan and abroad, regarding TPM technologies 5. Present awards for achievement in TPM technology 6 6 © Operational Excellence Consulting. All rights reserved.

Overview of TPM Excellence Model What is the Purpose of the TPM Excellence Award? • Promote the modernization of plant maintenance • Develop plant maintenance technologies • Help to develop Japan’s competitiveness 7 7 © Operational Excellence Consulting. All rights reserved.

Overview of TPM Excellence Model Benefits of Applying for TPM Recognition • Create enthusiasm for improvement • Instill a culture of excellence • Receive a blue print of your results • Independent self-assessment • Improve your competitiveness • International visibility and recognition 8 8 © Operational Excellence Consulting. All rights reserved.

Overview of TPM Excellence Model How is an Organization Selected as a TPM Winner? • Evaluation is based on how the organization is run (approach and deployment) and on the basis of performance (results) ▪ Self-assessment Criteria ▪ Self-assessment Checklist (10 key areas) • Every major part of the organization is assessed • Strong commitment to continuous improvement 9 9 © Operational Excellence Consulting. All rights reserved.

Overview of TPM Excellence Model JIPM TPM Award Categories Award for World-class TPM Achievement Advanced Special Award for TPM Achievement Advanced Special Award for TPM Achievement Advanced Special Award for TPM Achievement Special Award for TPM Achievement Award for Excellence in Consistent TPM Commitment Award for TPM Excellence – Category A Award for TPM Excellence – Category B Source: JIPM 10 10 © Operational Excellence Consulting. All rights reserved.

Criteria for TPM Excellence TPM Excellence Model TPM Policies & Objectives Safety, Health & Environment Autonomous Maintenance Focused Improvement Planned Maintenance Education & Training Quality Maintenance TPM in the Office Early Equipment Management 5S & Visual Management 12 12 © Operational Excellence Consulting. All rights reserved.

Criteria for TPM Excellence Assessment Criteria (“Basic Conditions”) 1. Formulation of policy and target 8. Ensuring of top management diagnosis function 2. Formulation of master plan 9. Establishment of pillars of TPM implementation 3. Establishment of promotion system by top management 10.Clarification of loss 4. Manager and technical staff-led type formation of overlapping small groups 11.Utilization of methods and techniques to solve problems/ issues 5. Creation of opportunity for all members to participate 12.Utilization of tools for circle activation 6. Introduction of step-by-step implementation system 13.Establishment of system for developing human resources 7. Implementation of step-by-step examination 13 13 © Operational Excellence Consulting. All rights reserved.

Criteria for TPM Excellence 10 Assessment Areas 1. TPM Policies and Objectives 7. Training and Development 2. Individual Improvement 8. Administrative & Supervisory Departments 3. Autonomous Maintenance 9. Safety, Sanitation, & Environmental Control 4. Planned Maintenance 5. Quality Maintenance 10. Effects and Evaluation of TPM 6. Product & Equipment Development & Control Note: Items 2 to 9 are equivalent to the eight TPM pillars 14 14 © Operational Excellence Consulting. All rights reserved.

Criteria for TPM Excellence Approach • “Approach” refers to how the organization addresses the criteria requirements in terms of the methods, tools and techniques used. The factors used to evaluate approach include the following: ▪ Extent to which methods, tools and techniques are appropriate for the requirements ▪ Extent to which methods, tools and techniques are effective ▪ Degree to which the approach: ➢ is systematic, integrated and consistently applied; and ➢ is based upon information that is objective and reliable ▪ Evidence of innovation, including significant and effective adaptations of approaches used in other applications or types of business 16 16 © Operational Excellence Consulting. All rights reserved.

Criteria for TPM Excellence Deployment • “Deployment” refers to the extent to which the organization’s approach is applied, implemented and deployed within and outside the organization. The factors used to evaluate deployment include the following: ▪ Appropriate and effective use of the approach in key operational areas ▪ Appropriate and effective use of the approach in interactions with customers, employees, suppliers/partners of goods and services and the public 17 17 © Operational Excellence Consulting. All rights reserved.

Criteria for TPM Excellence Results • “Results” refers to the outcomes achieved by the organization. The factors used to evaluate results include the following: ▪ Current performance levels ▪ Performance levels relative to appropriate comparisons and/or benchmarks ▪ Rate, breadth and importance of performance improvements ▪ Linkages of results measures to key performance requirements identified in the Organizational Profile and Approach/Deployment criteria items 18 18 © Operational Excellence Consulting. All rights reserved.

3 Award Criteria Guidance Points C:\Users\Allan BigMac\Documents\000 OEC\Logo\The Logo Company\FINAL\OperationalExD24aR02bP01ZL\TRANSPARENT.png © Operational Excellence Consulting. All rights reserved.

Award Criteria Guidance Points Guidance Points for Each Checklist Item • There are 10 categories or evaluation areas. Although an equal weightage system is used in this self-assessment tool, users are free to vary the weightage as they deem appropriate. • Each category or evaluation area has 10 checklist items. NONE REACTIVE DEFINED INTEGRATED REFINED INNOVATIVE APPROACH NONE SOME SOME KEY MOST KEY ALL KEY EXCEEDED TARGET ALL DEPLOYMENT NONE INCONSISTENT POSITIVE MET TARGET EXCEPTIONAL RESULTS POINTS 0 2 4 6 8 10 ? 21 21 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines Scoring Guidelines NONE REACTIVE DEFINED INTEGRATED REFINED INNOVATIVE APPROACH NONE SOME SOME KEY MOST KEY ALL KEY EXCEEDED TARGET ALL DEPLOYMENT NONE INCONSISTENT POSITIVE MET TARGET EXCEPTIONAL RESULTS TPM Policies and Objectives Individual Improvement Three dimensions of evaluation Autonomous Maintenance Planned Maintenance Quality Ten areas of assessment Maintenance Product & Equipment Devt & Control Training and Development Administrative & Supervisory Departments Safety, Sanitation, & Environmental Six scoring bands Control Effects and Evaluation of TPM BAND 1 2 3 4 5 6 SCORE 0 1 - 199 200 - 399 400 – 599 600 – 799 800 - 1000 ? 23 23 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines Scoring Guidelines – Bands 1, 2 & 3 Score Band Approach Deployment Results There are no results, or results show no improvement trends and have not met targets. Poor results. Improvement trends and/or good performance levels for a few key indicators. Results not reported for most key indicators. Improvement trends and/or good performance levels for some key indicators. Early stages of obtaining comparative information. Results reported for some key indicators. There is no approach at all. 0 1 There is no deployment. Some form of approach exists but it is reactive and not systematic. Approach is deployed to few areas of the organization. 1-199 2 Direction for approach is defined. Beginning of a planned and prevention-based approach. Approach is deployed to some key areas of the organization. 200-399 3 ? 24 24 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines Scoring Guidelines – Bands 4 & 5 Score Band Approach Deployment Results Improvement trends and/or current performance levels are good for most key indicators. Favourable comparisons and/ or benchmarks in some areas. Results reported for most key indicators. Current performance levels are good to excellent for most key indicators. Improvement trends are sustained in most areas. Favourable comparisons and/or benchmarks in key areas. Results reported for all key indicators. A sound, effective approach is in place with evidence of prevention activities. Approach is aligned with basic organizational needs identified in other criteria categories. Approach is deployed to most key areas of the organization. 400-599 4 A proven and well-defined approach with evidence of refinement through learning and improvement. Approach is well- integrated with organizational needs identified in other criteria categories. Approach is deployed to all key areas of the organization. Practised consistently by all levels. 600-799 5 ? 25 25 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines Scoring Guidelines – Band 6 Score Band Approach Deployment Results Current performance levels are excellent for most key indicators. Exceptional improvement trends in most areas. Exceptional comparisons and/or benchmarks in most areas. Results reported for all indicators. Exceptionally well-defined, innovative approach. Approach is accepted as best practice in the field. Approach is fully integrated with organizational needs identified in other criteria categories. Approach is deployed to all areas within and outside the organization. Practised consistently by all levels. 800-1000 6 ? 26 26 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines Anatomy of the TPM Self-assessment Checklist INTEGRATED INNOVATIVE REACTIVE DEFINED REFINED APPROACH Evaluation Dimensions NONE Six Bands of Evaluation (see Scoring Guidelines) SOME KEY MOST KEY ALL KEY DEPLOYMENT SOME NONE ALL BAND 1 2 3 4 5 6 1 TPM POLICIES & OBJECTIVES TPM policies are planned in relation between company policies and plant/factory policy. The relation between TPM target values and management target results are clear. 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. 10 The achievement status of TPM objectives is confirmed and necessary actions are taken for unachieved indexes. 1 Assessment Area 0 2 4 6 8 10 2 0 2 4 6 8 10 3 0 2 4 6 8 10 4 Points Distribution 0 2 4 6 8 10 Checklist Items 5 0 2 4 6 8 10 6 0 2 4 6 8 10 7 0 2 4 6 8 10 8 0 2 4 6 8 10 9 Each category carries a maximum of 100 points 0 2 4 6 8 10 0 2 4 6 8 10 ? 27 27 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines How to Conduct the Self-assessment 1. The self-assessment tool comprises of statements that address specific criteria requirements of a TPM standard. 2. There are two types of statements in the self-assessment tool. These are statements that address the Approach and Deployment dimensions together and statements that address the Results dimension. 3. The statements are to be rated on a scale of 1 to 6 based on the scoring guidelines. The rating for each statement is to be written down next to each statement. 28 28 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines Guidelines on Using the Self-Assessment Tool 1. A copy of the self-assessment tool should be given to each member of the self-assessment team(s). 2. The self-assessment team(s) will need to convene one or more planning session(s) to decide on the procedures and schedule for carrying out the self-assessment exercise. 3. They will need to review the self-assessment tool to identify the basic information that needs to be gathered to facilitate the process of self-assessment. 29 29 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines Scoring Each Category and Item 1. For each of the 10 categories, go through each statement and give a score which is reflective of the approach and deployment status. Do the same for the results dimension. Score 42 INTEGRATED INNOVATIVE REACTIVE DEFINED REFINED APPROACH NONE SOME KEY MOST KEY ALL KEY DEPLOYMENT SOME NONE ALL BAND 1 2 3 4 5 6 1 TPM POLICIES & OBJECTIVES TPM policies are planned in relation between company policies and plant/factory policy. The relation between TPM target values and management target results are clear. 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. 10 The achievement status of TPM objectives is confirmed and necessary actions are taken for unachieved indexes. 1 0 2 4 6 8 10 2 0 2 4 6 8 10 3 2. Add up all the item scores to get the total score for the category. In this example, the total score for Category 1 = 6+4+4+2+4+4+6+4+4+4 = 42 which is closest to Band 3. 0 2 4 6 8 10 4 0 2 4 6 8 10 5 0 2 4 6 8 10 6 0 2 4 6 8 10 7 0 2 4 6 8 10 8 0 2 4 6 8 10 9 0 2 4 6 8 10 3. Do the same for categories 2 to 10. 0 2 4 6 8 10 ? 30 30 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines Scoring Each Category and Item 4. Next, on the Overall Score page, shade Category 1 – ‘TPM Policies & Objectives’ under Band 3. NONE REACTIVE DEFINED INTEGRATED REFINED INNOVATIVE APPROACH NONE SOME SOME KEY MOST KEY ALL KEY EXCEEDED TARGET ALL DEPLOYMENT NONE INCONSISTENT POSITIVE MET TARGET EXCEPTIONAL RESULTS TPM Policies and Objectives Individual Improvement Autonomous Maintenance 5. Do the same for the other categories. Planned Maintenance Quality Maintenance Product & Equipment Devt & 6. Finally, add up all the category scores to obtain the Overall Band and Overall Score to compute the result for the organization. Control Training and Development Administrative & Supervisory Departments Safety, Sanitation, & Environmental Control Effects and Evaluation of TPM BAND 1 2 3 4 5 6 SCORE 0 1 - 199 200 - 399 400 – 599 600 – 799 800 - 1000 ACTUAL SCORE ? 31 31 © Operational Excellence Consulting. All rights reserved.

Scoring Guidelines Writing the Strengths & Areas for Improvement • For each category of self-assessment, write down the strengths and areas for improvement. The strengths identified should relate to the top 2-3 scoring statements. Similarly, the areas for improvement identified should be related to the lowest 2-3 scoring statements. • As a benchmark, in order to be ready for the TPM Excellence Award (Consistent TPM Commitment, Category A & Category B), you should aim to achieve at least 700 points or Band 5 for the organization or 70% of the points for each category. 32 32 © Operational Excellence Consulting. All rights reserved.

TPM Self-assessment Role of Self-Assessment Team • The self-assessment team should comprise six to eight members, who represent key staff in the organization • Alternatively, the organization could form different assessment groups to examine the different criteria categories in the self- assessment tool • The self-assessment teams should examine all areas based on the assessment criteria • All team members should have a good understanding of the assessment criteria 34 34 © Operational Excellence Consulting. All rights reserved.

TPM Self-assessment The Self-assessment Cycle Plan the Self- assessment Monitor Progress Train the Participants Engage Management Team Conduct the Self- assessment Develop Action Plans Agree Priorities 35 35 © Operational Excellence Consulting. All rights reserved.

Post TPM Self-assessment Follow-up Actions 1. Receive Feedback Report 2. Study Strengths and Areas for Improvement 3. Draw up Action Plans to address Areas for Improvement 4. Continue to consolidate Strengths 5. Set targets to achieve key milestones 37 37 © Operational Excellence Consulting. All rights reserved.

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TPM Self-Assessment Guidebook & Tool

TPM Self-Assessment Guidebook & Tool

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