TPM (TOTAL PRODUCTIVE MAINTENANCE) CHECKLIST

Created by ChecklistGuro (https://checklistguro.com)


--- AUTONOMOUS MAINTENANCE (JISHU HOZEN) ---
[ ] Date of Last Cleaning
[ ] Description of Cleaning Performed
[ ] Time Spent on Cleaning (minutes)
[ ] Any Abnormal Noises/Vibrations Observed?
[ ] Leaks Observed (Oil, Water, etc.) - Location & Type
[ ] Lubricant Level Check (if applicable) (Full, Low, Overfilled, Not Applicable)
[ ] Visual Inspection Items Checked (Guards in Place, Hoses & Fittings, Belts & Chains, Wiring & Cables, Fasteners, Overall Cleanliness)
[ ] Next Scheduled Autonomous Maintenance Date
[ ] Operator Comments/Observations

--- PLANNED MAINTENANCE (SEISO/INSPECTIONS) ---
[ ] Last Cleaning Date
[ ] Cleaning Notes (Areas cleaned, issues found)
[ ] Lubricant Quantity (Units)
[ ] Lubricant Type (Type A, Type B, Type C)
[ ] Vibration Reading (mm/s)
[ ] Visual Inspection Result (Normal, Minor Wear, Significant Wear, Damage)
[ ] Detailed Inspection Comments
[ ] Next Lubrication Due Date
[ ] Inspection Photos (Optional)

--- FIXED/PREDICTIVE MAINTENANCE (KIKAKU HOZEN) ---
[ ] Last Vibration Analysis Date
[ ] Bearing Temperature (Celsius)
[ ] Motor Current (Amps)
[ ] Pressure Readings (PSI)
[ ] Lubricant Type (Oil, Grease, Synthetic, Other)
[ ] Notes from Previous Predictive Maintenance
[ ] Infrared Image (if applicable)
[ ] Time of Last Oil Sample Analysis
[ ] Condition of Filter (Visual) (Excellent, Good, Fair, Poor)

--- EARLY FAILURE DETECTION (YOJU KANRI) ---
[ ] Bearing Temperature (Celsius)
[ ] Vibration Level (mm/s)
[ ] Motor Current (Amps)
[ ] Unusual Noise Observed? (Yes, No, Unsure)
[ ] Describe any unusual noises or behaviors.
[ ] Lubricant Condition (Visual Inspection) (Clean, Slightly Discolored, Discolored, Contaminated)
[ ] Date of Last Leak Detection Inspection
[ ] Any anomalies detected during inspection (detailed notes)

--- SAFETY & ERGONOMICS (ANZENSEN): ---
[ ] PPE (Personal Protective Equipment) Utilized? (Safety Glasses, Gloves, Hearing Protection, Safety Shoes, Respirator, High-Visibility Vest)
[ ] Noise Level (dB) during maintenance
[ ] Ergonomic Risk Assessment Completed? (Yes, No, N/A)
[ ] Any ergonomic concerns observed?
[ ] Lockout/Tagout (LOTO) Procedure followed? (Yes, No, N/A)
[ ] Last Ergonomic Risk Assessment Date
[ ] Incident/Near Miss Reporting (if applicable)
[ ] Areas requiring ergonomic improvements? (Lifting, Repetitive Motions, Awkward Postures, Forceful Exertions, Vibration)

--- MAINTENANCE PLANNING & PREPARATION (MITASHI HOZEN) ---
[ ] Planned Maintenance Date
[ ] Planned Maintenance Start Time
[ ] Estimated Maintenance Time (hours)
[ ] Detailed Maintenance Procedure/Steps
[ ] Required Tools (Wrenches, Screwdrivers, Specialized Tools, Calibration Equipment, Other)
[ ] Required Spare Parts (Filter A, Bearing B, Seal C, Belt D, Other Parts)
[ ] Maintenance Checklist/Diagram
[ ] Notes/Comments regarding preparation

--- EQUIPMENT IMPROVEMENT (KAIZEN) ---
[ ] Describe any design changes implemented to reduce maintenance frequency.
[ ] Estimated cost savings from implemented equipment improvements (USD).
[ ] Which improvement techniques were used (e.g., FMEA, 5S, Poke-yoke)? (FMEA (Failure Mode and Effects Analysis), 5S, Poke-yoke (Mistake-proofing), DFMEA (Design Failure Mode and Effects Analysis), PFMEA (Process Failure Mode and Effects Analysis), Other (Specify in LONG_TEXT))
[ ] Detail any changes made to reduce the complexity of maintenance tasks.
[ ] Reduction in MTBF (Mean Time Between Failures) due to improvement (hours).
[ ] Date of Kaizen implementation.
[ ] Describe any changes made to equipment materials to increase lifespan or reduce corrosion.

--- TRAINING & DOCUMENTATION ---
[ ] Maintenance Procedure Review & Updates
[ ] Hours of TPM Training Completed (per operator)
[ ] Date of Last TPM Training Session
[ ] TPM Training Modules Covered (Autonomous Maintenance, Planned Maintenance, Fixed/Predictive Maintenance, Early Failure Detection, Safety & Ergonomics, Maintenance Planning, Equipment Improvement)
[ ] Upload Training Records (certificates, attendance sheets)
[ ] Trainer Qualification Level (Certified TPM Trainer, Experienced Maintenance Technician, Other (Specify in LONG_TEXT))
[ ] Specify 'Other' Trainer Qualification (if selected)
[ ] Date of last documentation review

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