The item measures of the TPM pillars and OEE
| Construct | Item code | Items |
|---|---|---|
| Autonomous Maintenance (AM) | AM1 | In our company, machine operators have given the responsibility/autonomy/for basic maintenance tasks, rather than relying on dedicated maintenance technicians. Operators perform maintenance tasks on their own equipment emphasizing proactive and preventative maintenance |
| AM2 | The operators are empowered and able to do simple maintenance tasks (cleaning, lubrication, fixing minor errors, tightening nuts and bolts and safety checks) themselves | |
| AM3 | Our company tools required to perform routine maintenance, checks, setups, etc., are identified and stored using 6S (sort, set in order, shine/sweep, standardize, sustain and safety) principles | |
| Education and Training (EduT) | EdT1 | In our company, operators are given necessary education and training on maintenance engineering practices timely |
| EdT2 | All employees associated with the focus equipment value stream (operators, supervisors, management, quality assurance, engineering, maintenance, etc) received proper training and they have the necessary skills and knowledge | |
| EdT3 | In our company, all maintenance related training/operating materials are available and accessible to the concerned person | |
| EdT4 | In our company, maintenance skills gaps are identified, prioritized and filled through training timely | |
| Safety, Health and Environmental Management (SHE) | SHE1 | In our company, there is good maintenance management which avoids accidents during maintenance activities |
| SHE2 | In our company, all maintenance activities are environmentally friendly | |
| SHE3 | Environmental, health and safety (EHS) risk assessment associated with the equipment (machine guarding, electrical hazards, personal protective equipment (PPE) assessments, etc) is reviewed and updated timely | |
| SHE4 | All operators, mechanics, technicians (and others as appropriate), have been informed of all specific environmental, health and safety (EHS) hazards and associated control measurements that must be maintained | |
| Overall Equipment Effectiveness (OEE) | OEE1 | Our machines produce high quality/defect free/products |
| OEE2 | The performance of our machines is very high. Our machines are effective and efficient | |
| OEE3 | Our machines run for a long time without failure. The availability of our machines is high | |
| Planned Maintenance (PM) | PM1 | In our company, problems are fixed at the right time while they are minor to reduce repair costs |
| PM2 | Properly planned maintenance practices are being performed | |
| PM3 | Preventative maintenance requirements have been established for the equipment at a defined frequency | |
| PM4 | Critical spare parts have been identified and are stored near the equipment (as appropriate) | |
| PM5 | There are sufficient signs and labels that play a crucial role in a successful planned maintenance system. For example, every lubrication points have been labeled to identify the type of lubrication that should be used | |
| Early Equipment Management (EEM) | EEM1 | When it's time to choose new equipment or develop new products, we consider previous experiences to make maintenance easier in the new machine |
| EEM2 | There is an effort to design our machines for easy, infrequent and inexpensive maintenance | |
| EEM3 | Life cycle costs are considered in early management process with variable results | |
| EEM4 | There is an effort to design our machine for safety. For example, an effort to protect an operator from injury during machine breakdown | |
| Quality Maintenance (QM) | QM1 | In our company, cost of poor-quality losses is measured and addressed linking back to the process |
| QM2 | In our company, process capability issues are analyzed and investigated timely | |
| QM3 | In our company, product quality risks are managed timely and appropriately | |
| QM4 | Existing quality management systems and tools are used to identify and resolve issues affecting the quality factor of OEE | |
| Office TPM (OTPM) | OTPM1 | In our company, administrative workers and managers work in harmony with other employees |
| OTPM2 | Our administrative offices are responsive and flexible to respond to changes in our customer requirement and that ensured a strong brand image of the company | |
| OTPM3 | In our company offices, all tasks completed on time within standard working hours | |
| OTPM4 | There is clear and consistent communication between managers and employees about strategies and goals of maintenance which builds a strong foundation of manager-employee relationship in our company | |
| OTPM5 | There is continuous process improvement practice in administrative offices | |
| Focused Improvement (FI) | FI1 | In our company, there are team-based, structured improvement activities, aimed to eliminate or reduce all possible losses to improve safety and productivity and reduce defects and production costs |
| FI2 | The maintenance team is proactive, willing to try new methods | |
| FI3 | There is great effort aiming at creating a continuous improvement culture in maintenance related activities | |
| FI4 | There is comprehensive loss analysis to measure and analyze the current maintenance related losses contributing to productivity, efficiency or cost loss | |
| FI5 | In our company, standards established for cleaning, inspection, lubrication and tightening operations |
| Construct | Item code | Items |
|---|---|---|
| Autonomous Maintenance (AM) | AM1 | In our company, machine operators have given the responsibility/autonomy/for basic maintenance tasks, rather than relying on dedicated maintenance technicians. Operators perform maintenance tasks on their own equipment emphasizing proactive and preventative maintenance |
| AM2 | The operators are empowered and able to do simple maintenance tasks (cleaning, lubrication, fixing minor errors, tightening nuts and bolts and safety checks) themselves | |
| AM3 | Our company tools required to perform routine maintenance, checks, setups, etc., are identified and stored using 6S (sort, set in order, shine/sweep, standardize, sustain and safety) principles | |
| Education and Training (EduT) | EdT1 | In our company, operators are given necessary education and training on maintenance engineering practices timely |
| EdT2 | All employees associated with the focus equipment value stream (operators, supervisors, management, quality assurance, engineering, maintenance, etc) received proper training and they have the necessary skills and knowledge | |
| EdT3 | In our company, all maintenance related training/operating materials are available and accessible to the concerned person | |
| EdT4 | In our company, maintenance skills gaps are identified, prioritized and filled through training timely | |
| Safety, Health and Environmental Management (SHE) | SHE1 | In our company, there is good maintenance management which avoids accidents during maintenance activities |
| SHE2 | In our company, all maintenance activities are environmentally friendly | |
| SHE3 | Environmental, health and safety (EHS) risk assessment associated with the equipment (machine guarding, electrical hazards, personal protective equipment (PPE) assessments, etc) is reviewed and updated timely | |
| SHE4 | All operators, mechanics, technicians (and others as appropriate), have been informed of all specific environmental, health and safety (EHS) hazards and associated control measurements that must be maintained | |
| Overall Equipment Effectiveness (OEE) | OEE1 | Our machines produce high quality/defect free/products |
| OEE2 | The performance of our machines is very high. Our machines are effective and efficient | |
| OEE3 | Our machines run for a long time without failure. The availability of our machines is high | |
| Planned Maintenance (PM) | PM1 | In our company, problems are fixed at the right time while they are minor to reduce repair costs |
| PM2 | Properly planned maintenance practices are being performed | |
| PM3 | Preventative maintenance requirements have been established for the equipment at a defined frequency | |
| PM4 | Critical spare parts have been identified and are stored near the equipment (as appropriate) | |
| PM5 | There are sufficient signs and labels that play a crucial role in a successful planned maintenance system. For example, every lubrication points have been labeled to identify the type of lubrication that should be used | |
| Early Equipment Management (EEM) | EEM1 | When it's time to choose new equipment or develop new products, we consider previous experiences to make maintenance easier in the new machine |
| EEM2 | There is an effort to design our machines for easy, infrequent and inexpensive maintenance | |
| EEM3 | Life cycle costs are considered in early management process with variable results | |
| EEM4 | There is an effort to design our machine for safety. For example, an effort to protect an operator from injury during machine breakdown | |
| Quality Maintenance (QM) | QM1 | In our company, cost of poor-quality losses is measured and addressed linking back to the process |
| QM2 | In our company, process capability issues are analyzed and investigated timely | |
| QM3 | In our company, product quality risks are managed timely and appropriately | |
| QM4 | Existing quality management systems and tools are used to identify and resolve issues affecting the quality factor of OEE | |
| Office TPM (OTPM) | OTPM1 | In our company, administrative workers and managers work in harmony with other employees |
| OTPM2 | Our administrative offices are responsive and flexible to respond to changes in our customer requirement and that ensured a strong brand image of the company | |
| OTPM3 | In our company offices, all tasks completed on time within standard working hours | |
| OTPM4 | There is clear and consistent communication between managers and employees about strategies and goals of maintenance which builds a strong foundation of manager-employee relationship in our company | |
| OTPM5 | There is continuous process improvement practice in administrative offices | |
| Focused Improvement (FI) | FI1 | In our company, there are team-based, structured improvement activities, aimed to eliminate or reduce all possible losses to improve safety and productivity and reduce defects and production costs |
| FI2 | The maintenance team is proactive, willing to try new methods | |
| FI3 | There is great effort aiming at creating a continuous improvement culture in maintenance related activities | |
| FI4 | There is comprehensive loss analysis to measure and analyze the current maintenance related losses contributing to productivity, efficiency or cost loss | |
| FI5 | In our company, standards established for cleaning, inspection, lubrication and tightening operations |
Source(s): Adapted from (Al-refaie et al., 2022; Ahuja, 2009)
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