Total Productive Maintenance (TPM)

How do you track production output and cycle time against target on your critical equipment?

Level 1 → 5World class at level 4

1. 1We don't track parts produced vs target during the shift
2. 2We estimate total parts at the end of each shift
3. 3Manual hour-by-hour tally on paper or spreadsheet — target, actual, good, scrap
4. 4Tablet-based hour-by-hour tracking with target vs actual and cycle timeWorld class
5. 5Automatic part counters feed a live production board against target

How involved are your machine operators in basic equipment care?

Level 1 → 5World class at level 4

1. 1Operators only run the machine — all maintenance is done by specialists
2. 2Operators clean when they feel it is needed
3. 3Operators follow a basic cleaning checklist
4. 4Operators perform defined daily/weekly inspections and minor adjustmentsWorld class
5. 5Operators detect and address abnormalities before they become failures

When equipment fails unexpectedly, how do you investigate the root cause?

Level 1 → 5World class at level 4

1. 1We fix it and move on — no formal investigation
2. 2Informal discussion between technicians
3. 3Written record of what failed and what was done
4. 4Structured RCA (5-Why or fishbone) for significant failuresWorld class
5. 5RCA is standard practice for all unplanned events; findings update PM schedules

Which maintenance performance metrics do you review regularly?

Level 1 → 5World class at level 4

1. 1We don't track maintenance KPIs formally
2. 2We track downtime hours informally
3. 3We track MTBF, MTTR, or throughput vs target on a spreadsheet
4. 4KPIs are reviewed in a regular maintenance meeting with trend dataWorld class
5. 5Live KPI dashboard; targets set and reviewed monthly with improvement actions