STEP 2

TOTAL PRODUCTIVE
MAINTENANCE -
STEP 2 AUDIT
Planned Maintenance

This audit serves as requirement to ensure alignment to JIPM standards and also for progression in
the TPM cluster.
 PLANNED MAINTENANCE STEP 2

The purpose of this audit is to ensure the Step 2 requirements of Planned Maintenance are being fulfilled. The
requirements have been cross referenced with the Japan Institute of Plant Maintenance excellence award
criteria.

Rating Scale: major deviation or more = 0, minor deviation= 1, meet expectations =2, exceeding
expectations = 3, superior=4

STEP 2 PM DOCUMENTATION

REQUIREMENT SCORE RESPONSIBLE

Past breakdown history: Data is actively collected on all Planned Maintenance Pillar
failures/breakdowns for the model area and has been Head
collected over a period of time. Collected data is shown on
equipment logs or breakdown sheets.
Equipment ranking: A standard has been developed for Planned Maintenance Pillar
evaluating and ranking equipment based on criteria, such as Head
safety, quality, operability, maintainability, cost, etc.
Breakdown occurrence list: Data is collected on failure Planned Maintenance Pillar
numbers, frequencies, severities, MTBFs, MTTRs, Head
maintenance costs, etc.
Selected PM equipment: Equipment has been ranked Planned Maintenance Pillar
according to the evaluation standard and equipment for Head
planned maintenance has been chosen, based on the ranking,
frequency of failures, MTBF, MTTR or maintenance costs.
Why-why analysis: Evidence is available of why-why analyses Planned Maintenance Pillar
on failures. Head and team
Countermeasures: Improvements developed for reducing Planned Maintenance Pillar
failures, using any of the five countermeasures: restoring Head and team
basic conditions, keeping the operating conditions, restoring
deterioration, improving weak design and preventing human
errors.
Forecasting: Forecasting problems as a countermeasure to Planned Maintenance Pillar
failures, using MTTR, MTBF, TBM or CBM for selected PM Head and team
equipment (show evidence).
Goals for reducing breakdowns: Goals have been set for Planned Maintenance Pillar
reducing breakdowns through planned maintenance, with Head
targeted timing.
Activity plan: A plan has been prepared for carrying out the Planned Maintenance Pillar
activities to achieve the above goals. Head

Evidence requirements must be sought for each point to ensure the documentation is in use and active.

TPM STEP 2 AUDIT 1

STEP 2 PM PRACTICE EVIDENCE

REQUIREMENT SCORE RESPONSIBLE

Cleaning Exercise: Basic conditions of equipment are Autonomous Maintenance
maintained through TICL exercise at line side cleaning, Pillar Head
lubrication, inspection and minor repairs.
Knowledge Test 1 Pillar Heads or Shop Floor: What is the Planned Maintenance Pillar
difference between planned maintenance and reactive Head/Shop Floor
maintenance? PM - maintenance conducted at planned or
scheduled intervals. Reactive maintenance inspection and
periodic replacement is not performed. Equipment is run to
failure
Preventing deterioration: Name a task that team members Shop Floor
can perform to prevent/reverse deterioration. TICL
maintaining basic conditions of equipment; minor repairs;
report failures accurately; tagging.
Benefits of planned maintenance: Name a benefit of planned Planned Maintenance Pillar
maintenance. Maintain the quality of the part; Increase Head/Shop Floor
production up time; Reduce cost of operations; Reduce
amount of machinery required; Ensure equipment capability
and reliability.
Tag Register with Tag Count tracked over time: Tags are Red Tags AM Pillar Head
tracked. Dates for the tagging register must be validated to and White Tags FI Pillar
ensure daily checks with comments. There is maintenance Head
support of AM activities to maintain the basic condition of
machines.
MTBF and MTTR: Explain what MTBF and MTTR are (can be Planned Maintenance Pillar
explained through the calculation). MTBF Adding the total Head
operating time and dividing by the number of failures, to
give the average amount of machine up time, before a
failure occurs. MTTR Adding the total repair time and
dividing by the number of failures, to give the average
amount of repair time taken for the breakdown/failure.

FOCUSSED IMPROVEMENT STEP 1-7

FOCUSSED IMPROVEMENT AUDIT

REQUIREMENT SCORE RESPONSIBLE

Kaizen A3 Summary Sheet: Focussed Improvement
- Kaizens for improvements in MTTR and MTBF, Pillar Head
- Kaizens for improving maintainability and reliability of
equipment,
- Kaizens focussing on the elimination of environment
causing forced deterioration,
- Kaizens have been closed off showing some results
to date of improvement.
Stepped FI plan with a list of all projects: Focussed Improvement
A detailed list of projects, expected completion date, Pillar Head
responsible parties.
TPM STEP 2 AUDIT 2
Visual Board Update: All projects presented onto the visual Focussed Improvement
board and tracked as per the weekly meetings. Team Pillar Head
structures.
Training and Development Matrix: Who has been trained, Education and Training
what is their level of competence towards TPM? The matrix Pillar Head
should follow a competency check.

STEERING COMMITTEE REQUIREMENTS

REQUIREMENT SCORE RESPONSIBLE
Declaration: A company communication stipulating the Focussed Improvement
objectives and commitment to TPM. Pillar Head
PM Team Structures: Officiated organograms outlining team Focussed Improvement
structures for the PM pillars. Pillar Head
KPIs: All projects and training are required to have KPIs Focussed Improvement
linked to a master KPI allocation. These are then cross Pillar Head
referenced with Kaizen events and PM activities.

TOTAL SCORE :

PERCENTAGE :

RESULT :

COMMENTS

AUDITORS:

PILLAR HEADS

STEERING COMMITTEE TEAM:

TPM STEP 2 AUDIT 3