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TPM Self-Assessment by Operational Excellence Consulting

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The Total Productive Maintenance (TPM) Excellence Award is conferred by the Japan Institute of Plant Maintenance (JIPM) to recognize organizations that have attained a high level of manufacturing excellence.

The TPM excellence initiative helps organizations to know where they are on the excellence journey and what they need to do to achieve a higher level of performance. This is done through a thorough assessment of organizational performance against the requirements of an internationally benchmarked TPM excellence framework.


HOW TO USE THE TPM SELF-ASSESSMENT GUIDE & TOOL

Use the guidebook to help you perform the TPM self-assessment process. Use the tool to benchmark your organization's TPM performance in ten areas of evaluation based on the TPM excellence criteria and checklist items. The total score will give you a baseline of where you are, and the identified strengths and areas for improvement will help you chart an action plan to improve overall performance.


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


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

Note: This package comes with a TPM self-assessment guidebook (PowerPoint format) and a TPM self-assessment tool (Word format).

TO DOWNLOAD THIS GUIDE & TOOL, PLEASE VISIT: http://www.oeconsulting.com.sg

Published in: Business

TPM Self-Assessment by Operational Excellence Consulting

  1. 1. © Operational Excellence Consulting. All rights reserved. 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.
  2. 2. © Operational Excellence Consulting. All rights reserved. 2 Objectives By the end of this self-assessment program, you will be able to: • Understand the TPM framework based on the JIPM standard for world-class manufacturing excellence • Define the TPM Criteria and Evaluation Areas • Describe the Point Values and Scoring Guidelines • Conduct a systematic TPM self-assessment and identify areas for improvement • Establish a baseline position so you can measure your progress over time NOTE: This is a PARTIAL PREVIEW. To download the complete guide and tool, please visit: http://www.oeconsulting.com.sg
  3. 3. © Operational Excellence Consulting. All rights reserved. 3 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
  4. 4. © Operational Excellence Consulting. All rights reserved. Overview of the TPM Excellence Model 1
  5. 5. © Operational Excellence Consulting. All rights reserved. 5 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 Overview of TPM Excellence Model Note: JIPM = Japan Institute of Plant Maintenance
  6. 6. © Operational Excellence Consulting. All rights reserved. 6 Objectives of JIPM • Research and development in production technologies • Collect and disseminate information and materials about production technologies • Certify skills for production activities • Exchange information with various organizations, both in Japan and abroad, regarding TPM technologies • Present awards for achievement in TPM technology Overview of TPM Excellence Model
  7. 7. © Operational Excellence Consulting. All rights reserved. 7 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 Overview of TPM Excellence Model
  8. 8. © Operational Excellence Consulting. All rights reserved. 8 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 Overview of TPM Excellence Model
  9. 9. © Operational Excellence Consulting. All rights reserved. 9 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 Overview of TPM Excellence Model
  10. 10. © Operational Excellence Consulting. All rights reserved. 10 TPM Award Categories Overview of TPM Excellence Model
  11. 11. © Operational Excellence Consulting. All rights reserved. Criteria for TPM Excellence 2
  12. 12. © Operational Excellence Consulting. All rights reserved. 12 TPM Excellence Model TPMintheOffice Safety,Health&Environment AutonomousMaintenance PlannedMaintenance FocusedImprovement EarlyEquipment Management QualityMaintenance Education&Training 5S & Visual Management TPM Policies & Objectives Criteria for TPM Excellence
  13. 13. © Operational Excellence Consulting. All rights reserved. 13 Assessment Criteria (“Basic Conditions”) 1. Formulation of policy and target 2. Formulation of master plan 3. Establishment of promotion system by top management 4. Manager and technical staff-led type formation of overlapping small groups 5. Creation of opportunity for all members to participate 6. Introduction of step-by-step implementation system 7. Implementation of step-by-step examination 8. Ensuring of top management diagnosis function 9. Establishment of pillars of TPM implementation 10.Clarification of loss 11.Utilization of methods and techniques to solve problems/ issues 12.Utilization of tools for circle Activation 13.Establishment of system for developing human resources Criteria for TPM Excellence
  14. 14. © Operational Excellence Consulting. All rights reserved. 14 10 Assessment Areas 1. TPM Policies and Objectives 2. Individual Improvement 3. Autonomous Maintenance 4. Planned Maintenance 5. Quality Maintenance 6. Product & Equipment Development & Control 7. Training and Development 8. Administrative & Supervisory Departments 9. Safety, Sanitation, & Environmental Control 10.Effects and Evaluation of TPM Note: Items 2 to 9 are equivalent to the eight TPM pillars Criteria for TPM Excellence
  15. 15. © Operational Excellence Consulting. All rights reserved. 15 Three Integrated Components Approach Deployment Results Criteria for TPM Excellence
  16. 16. © Operational Excellence Consulting. All rights reserved. 16 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. Criteria for TPM Excellence
  17. 17. © Operational Excellence Consulting. All rights reserved. 17 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. Criteria for TPM Excellence
  18. 18. © Operational Excellence Consulting. All rights reserved. 18 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 Criteria for TPM Excellence
  19. 19. © Operational Excellence Consulting. All rights reserved. Award Criteria Guidance Points 3
  20. 20. © Operational Excellence Consulting. All rights reserved. 20 Guidance Points for the 10 Areas of Evaluation Award Criteria Guidance Points
  21. 21. © Operational Excellence Consulting. All rights reserved. 21 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. Award Criteria Guidance Points APPROACH NONE REACTIVE DEFINED INTEGRATED REFINED INNOVATIVE DEPLOYMENT NONE SOME SOME KEY MOST KEY ALL KEY ALL RESULTS NONE INCONSISTENT POSITIVE MET TARGET EXCEEDED TARGET EXCEPTIONAL POINTS 0 2 4 6 8 10
  22. 22. © Operational Excellence Consulting. All rights reserved. Scoring Guidelines 4
  23. 23. © Operational Excellence Consulting. All rights reserved. 23 Scoring Guidelines Scoring Guidelines APPROACH NONE REACTIVE DEFINED INTEGRATED REFINED INNOVATIVE DEPLOYMENT NONE SOME SOME KEY MOST KEY ALL KEY ALL RESULTS NONE INCONSISTENT POSITIVE MET TARGET EXCEEDED TARGET EXCEPTIONAL TPM Policies and Objectives Individual Improvement Autonomous Maintenance Planned Maintenance Quality Maintenance Product & Equipment Devt & 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 Three dimensions of evaluation Ten areas of assessment Six scoring bands
  24. 24. © Operational Excellence Consulting. All rights reserved. 24 Scoring Guidelines – Bands 1, 2 & 3 Scoring Guidelines Score Band Approach Deployment Results 0 1 There is no approach at all. There is no deployment. There are no results, or results show no improvement trends and have not met targets. 1-199 2 Some form of approach exists but it is reactive and not systematic. Approach is deployed to few areas of the organization. Poor results. Improvement trends and/or good performance levels for a few key indicators. Results not reported for most key indicators. 200-399 3 Direction for approach is defined. Beginning of a planned and prevention-based approach. Approach is deployed to some key areas of the organization. Improvement trends and/or good performance levels for some key indicators. Early stages of obtaining comparative information. Results reported for some key indicators.
  25. 25. © Operational Excellence Consulting. All rights reserved. 25 Scoring Guidelines – Bands 4 & 5 Scoring Guidelines Score Band Approach Deployment Results 400-599 4 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. 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. 600-799 5 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. 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.
  26. 26. © Operational Excellence Consulting. All rights reserved. 26 Scoring Guidelines – Band 6 Scoring Guidelines Score Band Approach Deployment Results 800-1000 6 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. 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.
  27. 27. © Operational Excellence Consulting. All rights reserved. 27 Anatomy of Self-assessment Checklist APPROACH NONE REACTIVE DEFINED INTEGRATED REFINED INNOVATIVE DEPLOYMENT NONE SOME SOMEKEY MOSTKEY ALLKEY ALL BAND 1 2 3 4 5 6 1 TPM POLICIES & OBJECTIVES 1 TPM policies are planned in relation between company policies and plant/factory policy. 0 2 4 6 8 10 2 The relation between TPM target values and management target results are clear. 0 2 4 6 8 10 3 The master plan is in an appropriate order as an action plan to achieve TPM. 0 2 4 6 8 10 4 TPM policies and objectives are checked using methods such as benchmarking that all sections of PQCDSME are displayed corresponding to 8 pillars. 0 2 4 6 8 10 5 TPM policies and objectives have been set forth and observed by all the departments and sections. 0 2 4 6 8 10 6 The achievement status of TPM policies and objectives is available in a time line using objective data. 0 2 4 6 8 10 7 Overlapping small groups, the TPM promotion committee, and other special committees are organized in a way that leads to TPM activities. 0 2 4 6 8 10 8 TPM promotion units help facilitate TPM activities within departments/ sections. 0 2 4 6 8 10 9 Small groups on the front line have been vitalized. 0 2 4 6 8 10 10 The achievement status of TPM objectives is confirmed and necessary actions are taken for unachieved indexes. 0 2 4 6 8 10 Evaluation Dimensions Checklist Items Six Bands of Evaluation (see Scoring Guidelines) Points Distribution Assessment Area Scoring Guidelines Each category carries a maximum of 100 points
  28. 28. © Operational Excellence Consulting. All rights reserved. 28 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. Scoring Guidelines
  29. 29. © Operational Excellence Consulting. All rights reserved. 29 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. Scoring Guidelines
  30. 30. © Operational Excellence Consulting. All rights reserved. 30 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. 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. 3. Do the same for categories 2 to 10. Scoring Guidelines Score 42 APPROACH NONE REACTIVE DEFINED INTEGRATED REFINED INNOVATIVE DEPLOYMENT NONE SOME SOMEKEY MOSTKEY ALLKEY ALL BAND 1 2 3 4 5 6 1 TPM POLICIES & OBJECTIVES 1 TPM policies are planned in relation between company policies and plant/factory policy. 0 2 4 6 8 10 2 The relation between TPM target values and management target results are clear. 0 2 4 6 8 10 3 The master plan is in an appropriate order as an action plan to achieve TPM. 0 2 4 6 8 10 4 TPM policies and objectives are checked using methods such as benchmarking that all sections of PQCDSME are displayed corresponding to 8 pillars. 0 2 4 6 8 10 5 TPM policies and objectives have been set forth and observed by all the departments and sections. 0 2 4 6 8 10 6 The achievement status of TPM policies and objectives is available in a time line using objective data. 0 2 4 6 8 10 7 Overlapping small groups, the TPM promotion committee, and other special committees are organized in a way that leads to TPM activities. 0 2 4 6 8 10 8 TPM promotion units help facilitate TPM activities within departments/ sections. 0 2 4 6 8 10 9 Small groups on the front line have been vitalized. 0 2 4 6 8 10 10 The achievement status of TPM objectives is confirmed and necessary actions are taken for unachieved indexes. 0 2 4 6 8 10
  31. 31. © Operational Excellence Consulting. All rights reserved. 31 APPROACH NONE REACTIVE DEFINED INTEGRATED REFINED INNOVATIVE DEPLOYMENT NONE SOME SOME KEY MOST KEY ALL KEY ALL RESULTS NONE INCONSISTENT POSITIVE MET TARGET EXCEEDED TARGET EXCEPTIONAL TPM Policies and Objectives Individual Improvement Autonomous Maintenance Planned Maintenance Quality Maintenance Product & Equipment Devt & 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 Scoring Each Category and Item 4. Next, on the Overall Score page, shade Category 1 – ‘TPM Policies & Objectives’ under Band 3. 5. Do the same for the other categories. 6. Finally, add up all the category scores to obtain the Overall Band and Overall Score to compute the result for the organization. Scoring Guidelines
  32. 32. © Operational Excellence Consulting. All rights reserved. 32 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. Scoring Guidelines
  33. 33. © Operational Excellence Consulting. All rights reserved. TPM Self-assessment 5
  34. 34. © Operational Excellence Consulting. All rights reserved. 34 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. TPM Self-assessment
  35. 35. © Operational Excellence Consulting. All rights reserved. 35 Engage Management Team The Self-assessment Cycle TPM Self-assessment Plan the Self- assessment Train the Participants Conduct the Self- assessment Agree Priorities Develop Action Plans Monitor Progress
  36. 36. © Operational Excellence Consulting. All rights reserved. Post TPM Self-assessment 6
  37. 37. © Operational Excellence Consulting. All rights reserved. 37 Follow-up Actions • Receive Feedback Report • Study Strengths and Areas for Improvement • Draw up Action Plans to address Areas for Improvement • Continue to consolidate Strengths • Set targets to achieve key milestones Post TPM Self-assessment
  38. 38. © Operational Excellence Consulting. All rights reserved. About Operational Excellence Consulting
  39. 39. © Operational Excellence Consulting. All rights reserved. 39 About Operational Excellence Consulting • Operational Excellence Consulting is a management training and consulting firm that assists organizations in improving business performance and effectiveness. • The firm’s mission is to create business value for organizations through innovative operational excellence management training and consulting solutions. • OEC takes a unique “beyond the tools” approach to enable clients develop internal capabilities and cultural transformation to achieve sustainable world-class excellence and competitive advantage. For more information, please visit www.oeconsulting.com.sg
  40. 40. © Operational Excellence Consulting. All rights reserved. www.oeconsulting.com.sg END OF PARTIAL PREVIEW To download this complete self-assessment guidebook and tool, please visit:

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