Planned Maintenance
This audit serves as requirement to ensure alignment to JIPM standards and also for progression in the TPM cluster.
PLANNED MAINTENANCE STEP 1
The purpose of this audit is to ensure the Step 1 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 1 PM DOCUMENTATION
REQUIREMENT / SCORE / RESPONSIBLEPast breakdown history: Data is actively collected on all failures/breakdowns for the model area and has been collected over a period of time. Collected data is shown on equipment logs or breakdown sheets. / Planned Maintenance Pillar Head
Equipment ledgers:Data on breakdowns, maintenance and service history per machine in the pilot area, is maintained in an equipment ledger. / Planned Maintenance Pillar Head
Negative Map: Detailed schematic of the model area or plant, outlining areas where breakdowns/failures occurred over a given period. / Planned Maintenance Pillar Head
Equipment ranking:A standard has been developed for evaluating and ranking equipment based on criteria, such as safety, quality, operability, maintainability, cost, etc. / Planned Maintenance Pillar Head
Breakdown occurrence list: Data is collected on failure numbers, frequencies, severities, MTBFs, MTTRs, maintenance costs, etc. / Planned Maintenance Pillar Head
Selected PM equipment: Equipment has been ranked according to the evaluation standard and equipment for planned maintenance has been chosen, based on the ranking, frequency of failures, MTBF, MTTR or maintenance costs. / Planned Maintenance Pillar Head
Goals for reducing breakdowns: Goals have been set for reducing breakdowns through planned maintenance, with targeted timing. / Planned Maintenance Pillar Head
Activity plan: A plan has been prepared for carrying out the activities to achieve the above goals. / Planned Maintenance Pillar Head
Evidence requirements must be sought for each point to ensure the documentation is in use and activities.
STEP 1 PMPRACTICE EVIDENCE
REQUIREMENT / SCORE / RESPONSIBLECleaning Exercise: Cleaning exercise is being adhered to in line with the cleaning instruction for the area/equipment. / Autonomous Maintenance Pillar Head
Knowledge Test 1 Pillar Heads or Shop Floor:What is the difference between planned maintenance and reactive maintenance?PM - maintenance conducted at planned or scheduled intervals. Reactive maintenance – inspection and periodic replacement is not performed. Equipment is run to failure / Planned Maintenance Pillar Head/Shop Floor
Negative map: Explain the use of the negative map. Is there a negative map in the area that the team leader actively updates for every breakdown?A negative map is a map of the plant layout – each time there is an unplanned call out, a red pin is placed on that area on the map. / Planned Maintenance Pillar Head/Shop Floor
Benefits of planned maintenance: Name a benefit of planned maintenance.Maintain the quality of the part; Increase production up time; Reduce cost of operations; Reduce amount of machinery required; Ensure equipment capability and reliability. / Planned Maintenance Pillar Head/Shop Floor
Tag Register with Tag Count tracked over time:Tags are tracked. Dates for the tagging register must be validated to ensure daily checks with comments. Online registers may be provided with comments. / Red Tags – AM Pillar Head and White Tags – FI Pillar Head
MTBF and MTTR: Explain what MTBF and MTTR are (can be explained through the calculation).MTBF – Adding the totaloperating 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. / Planned Maintenance Pillar Head
STEERING COMMITTEE REQUIREMENTS
REQUIREMENT / SCORE / RESPONSIBLE
Declaration:A company communication stipulating the objectives and commitment to TPM. / Focussed Improvement Pillar Head
PM Team Structures: Officiatedorganograms outlining team structures for the PM pillars. / Focussed Improvement Pillar Head
KPI’s: All projects and trainingare required to have KPI’s linked to a master KPI allocation. These are then cross referenced with Kaizen events and PM activities. / Focussed Improvement Pillar Head
TOTAL SCORE :
PERCENTAGE :
RESULT :
COMMENTS
AUDITORS:
PILLAR HEADS
STEERING COMMITTEE TEAM:
TPM STEP 1 AUDIT / 1