TPM Self-Assessment Guide

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.
TPM Self-Assessment
Guidebook & Tool
© Operational Excellence Consulting. All rights reserved.

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© Operational Excellence Consulting. All rights reserved. 2
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
NOTE: This is a PARTIAL PREVIEW. To
download the complete presentation, please
visit: https://www.oeconsulting.com.sg

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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

Overview of the TPM Excellence Model
1

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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

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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

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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

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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

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

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JIPM TPM Award Categories
Source: JIPM
Award for World-class TPM
Achievement
Advanced Special Award
for TPM Achievement
for TPM Achievement
for TPM Achievement
Award for TPM Excellence –
Category B
Special Award for TPM
Achievement
Award for Excellence in
Consistent TPM
Commitment
Award for TPM Excellence –
Category A

Criteria for TPM Excellence
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TPM Excellence Model
TPM
in
the
Office
Safety,
Health
&
Environment
Autonomous
Maintenance
Planned
Maintenance
Focused
Improvement
Early
Equipment
Management
Quality
Maintenance
Education
&
Training
5S & Visual Management
TPM
Policies & Objectives

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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

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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

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Three Integrated Components
Approach
Deployment
Results

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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:
Ø is systematic, integrated and consistently applied; and
Ø 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

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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

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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

Award Criteria Guidance Points
3

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Guidance Points for the 10 Areas of Evaluation

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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.
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

Scoring Guidelines
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Scoring Guidelines
Scoring Guidelines
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

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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.
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.

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Scoring Guidelines – Bands 4 & 5
Scoring Guidelines
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.
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
categories.
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.

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Scoring Guidelines – Band 6
Scoring Guidelines
800-1000 6
Exceptionally well-defined,
innovative approach.
Approach is accepted as
best practice in the field.
Approach is fully
integrated with
organizational needs
categories.
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.

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Anatomy of the TPM Self-assessment Checklist
APPROACH
NONE
REACTIVE
DEFINED
INTEGRATED
REFINED
INNOVATIVE
DEPLOYMENT
NONE
SOME
SOME
KEY
MOST
KEY
ALL
KEY
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

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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

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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

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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
SOME
KEY
MOST
KEY
ALL
KEY
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

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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

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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

TPM Self-assessment
5

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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

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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

Post TPM Self-assessment
6

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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
Post TPM Self-assessment

Operational Excellence Consulting is a management training and consulting
firm that assists organizations in improving business performance and
effectiveness. Based in Singapore, the firm’s mission is to create business
value for organizations through innovative design and operational excellence
management training and consulting solutions. For more information, please
visit www.oeconsulting.com.sg

TPM Self-Assessment Guide

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