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Total Productive Maintenance (TPM) Audit Checklist

A comprehensive checklist to audit the implementation of Total Productive Maintenance principles in manufacturing facilities, ensuring maximum equipment effectiveness and operational efficiency.

Total Productive Maintenance (TPM) Audit Checklist
by: audit-now
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About This Checklist

The Total Productive Maintenance (TPM) Audit Checklist is a vital tool for manufacturing companies implementing Six Sigma methodologies to maximize equipment effectiveness and productivity. This comprehensive checklist evaluates the implementation of TPM principles across all aspects of maintenance and operations. By systematically assessing the eight pillars of TPM, organizations can enhance equipment reliability, reduce downtime, and improve overall operational efficiency. This checklist is designed to ensure proper integration of maintenance strategies with production goals, fostering a culture of continuous improvement and shared responsibility for equipment care.

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Industry

Manufacturing

Standard

Six Sigma

Workspaces

Manufacturing plant

Occupations

Maintenance Manager
Production Supervisor
Reliability Engineer
Equipment Operator
TPM Coordinator

TPM Effectiveness Assessment

(0 / 5)

1
How would you rate the reliability improvement of the equipment?

Select the reliability improvement level.

To assess the impact of TPM and maintenance strategies on reliability.
2
What Total Productive Maintenance initiatives have been implemented?

Describe the TPM initiatives undertaken.

To gather qualitative data on TPM efforts and improvements.
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3
How frequently is maintenance performed on this equipment?

Select the frequency of maintenance tasks.

To evaluate the maintenance strategy's effectiveness.
4
What is the total downtime duration for the equipment in the last month?

Enter the total downtime in hours.

To measure the impact of downtime on operational efficiency.
Min: 0
Target: 0
Max: 744
5
Is the equipment operating within the expected parameters?

Select the current operational status of the equipment.

To assess whether the equipment is functioning optimally.
6
How involved are employees in TPM initiatives?

Select the involvement level.

To measure employee participation in TPM activities.
7
What feedback have employees provided regarding TPM training?

Provide feedback received from employees.

To gather qualitative data on the effectiveness of training sessions.
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8
How would you rate employee engagement in TPM initiatives?

Select the engagement level.

To evaluate how engaged employees are in TPM processes.
9
How many TPM training sessions have been conducted in the last quarter?

Enter the number of sessions.

To assess the level of engagement and training efforts.
Min: 0
Target: 5
Max: 100
10
Have all relevant employees completed TPM training?

Select the training completion status.

To ensure that staff are adequately trained in TPM practices.
11
How effectively are TPM tools being utilized on this equipment?

Select the utilization level.

To assess the usage of TPM methodologies and tools.
12
Describe any recent performance issues experienced with the equipment.

Provide details of recent performance issues.

To identify and document any operational challenges.
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13
What is the current status of the maintenance backlog?

Select the backlog status.

To evaluate the maintenance workload and priorities.
14
What is the current condition rating of the equipment?

Select the condition rating.

To assess the physical state of the equipment.
15
What is the current Overall Equipment Effectiveness (OEE) percentage?

Enter the OEE percentage.

To quantify the effectiveness of equipment utilization.
Min: 0
Target: 85
Max: 100
16
Have any training needs been identified based on compliance reviews?

Select whether training needs have been identified.

To ensure that personnel are adequately trained to meet compliance standards.
17
What recommendations do you have for improving compliance?

Provide any suggestions for improvement.

To gather insights on potential enhancements to compliance practices.
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18
What is the status of any recent audit findings?

Select the status of audit findings.

To determine the resolution of issues identified in previous audits.
19
How many deviations from the SOPs have been recorded in the last month?

Enter the total number of deviations.

To track instances of non-compliance and areas for improvement.
Min: 0
Target: 0
Max: 100
20
Are all Standard Operating Procedures (SOPs) being followed for maintenance?

Select the compliance status.

To ensure compliance with established procedures and standards.
21
How would you rate management support for continuous improvement initiatives?

Select the rating of management support.

To assess the level of management involvement in improvement efforts.
22
What barriers to continuous improvement have been identified?

Describe any barriers encountered.

To understand challenges faced in implementing improvements.
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23
How effective have recent improvement projects been?

Select the effectiveness rating.

To evaluate the impact of implemented improvement projects.
24
How many improvement suggestions have been submitted by employees?

Enter the total number of suggestions submitted.

To gauge employee involvement in the continuous improvement process.
Min: 0
Target: 10
Max: 100
25
What continuous improvement initiatives have been implemented in the last quarter?

Select the status of continuous improvement initiatives.

To assess the engagement in ongoing improvement efforts.

FAQs

The audit should involve maintenance managers, production supervisors, equipment operators, reliability engineers, and representatives from quality and safety departments.

The primary purpose is to assess and improve the implementation of Total Productive Maintenance principles in manufacturing facilities, ensuring maximum equipment effectiveness and operational efficiency.

TPM audits should be conducted regularly, typically quarterly or semi-annually, to maintain momentum and identify areas for continuous improvement in maintenance practices.

The checklist covers the eight pillars of TPM: autonomous maintenance, planned maintenance, quality maintenance, focused improvement, early equipment management, training and education, safety and environment, and TPM in administrative departments.

By ensuring proper implementation of TPM principles, the audit helps improve equipment reliability, reduce waste, increase productivity, and ultimately lead to enhanced product quality and customer satisfaction in manufacturing operations.

Benefits

Ensures comprehensive implementation of TPM principles across all equipment and processes

Identifies opportunities for improving Overall Equipment Effectiveness (OEE)

Reduces unplanned downtime and maintenance costs

Enhances equipment lifespan and reliability

Promotes cross-functional collaboration between maintenance and production teams