Total Productive Maintenance (TPM) Audit

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Strengthen your TPM Culture and prepare for TPM Excellence Award with Comprehensive TPM Audit

TPM audit is a crucial tool for assessing and improving Total Productive Maintenance (TPM) practices in any organization. Total Productive Maintenance or TPM is a comprehensive approach to improve efficiency, productivity and reliability of the equipment throughout its entire lifecycle. To maximise the equipment effectiveness, TPM aims at achieving zero breakdowns, zero defects and zero accidents by eliminating 16 Major losses, which obstruct production efficiency.

A TPM audit is conducted to assess the effectiveness of TPM implementation, identify areas for improvement and provide recommendations to enhance equipment efficiency, reduce downtime, lower costs, and improve overall operational performance. 

By regularly conducting TPM audits, companies can identify potential issues before they lead to significant problems, foster a proactive maintenance culture, and align their efforts with business objectives, ultimately driving long-term success.Through a structured process and methodology, a TPM audit drives continuous improvement, employee engagement, and cost savings across the organization.


Why is TPM Audit critical for your organisation?

Identify gaps to Improve effectiveness of TPM pillars

Identify key improvements to enhance readiness for TPM Excellence Awards

Evaluate OEE to optimize machine performance and reduce equipment failures

Identify potential breakdown risks to prevent downtime & lower maintenance costs

Ensure quality of documentation for off site and on site TPM award assessment by JIPM


Our TPM Audit Approach

Our TPM Audit approach is directed towards identifying gaps in current TPM processes with clearly defined goals to achieve TPM Excellence and lays the foundation for a more efficient, productive, and cost-effective operation.

Current Performance Evaluation

  • Review of TPM policies, strategic targets, TPM Master Plan, and organizational structure of Steering Committee & TPM Pillar Committees
  • Data analysis of TPM pillar KPIs against defined targets to identify trends, gaps, and improvement opportunities.

Gemba Gap Analysis

  • Assessment of machine conditions and verification of TPM pillar activity implementation
  • Evaluation of 5S practices and visual management
  • Assessment of TPM awareness and competency levels

Improvement Roadmap

  • Preparation of a detailed TPM audit report highlighting key findings and improvement priorities.
  • Development of a targeted action plan to address identified gaps, including training and completion of pillar activities in line with JIPM standards.

Handholding for TPM Implementation

  • On-ground support for implementation of TPM initiatives based on audit findings
  • Expert assistance in preparation and submission for TPM award applications
  • Hands-on support during JIPM audit visits to ensure alignment with award criteria

TPM Audit Score

In order to assess the effectiveness of TPM, an audit score is calculated across different parameters to evaluate the maturity of TPM implementation, identify gaps and guide improvements.

  • TPM Policies and Objectives
  • Effects and Evaluation of TPM
  • Autonomous Maintenance
  • Kobetsu Kaizen
  • Early Equipment Management 
  • Planned Maintenance
  • Quality Maintenance
  • Safety, Sanitation and Environmental Control
  • TPM in Support departments
  • Training & Development


What to Expect

Objective Readiness Check

Know where you stand in your TPM journey and whether you’re ready for award-level evaluation

Expert Guidance

Gain insights from TPM-certified consultants with deep experience across industries to close gaps on TPM pillars execution & documentation

Strategic Action Plan

Focused roadmap with practical initiatives to accelerate progress and close critical gaps on TPM pillars activities and KPIs

Higher Success Probability

Improve your chances of success in achieving national and international TPM recognition


Our Clients Results

CASE STUDY

Large Textile & Paper manufacturer strengthens OEE and Cost Performance through TPM Audit

TPM Audit

A comprehensive multi-plant TPM assessment across yarn, towel, paper, energy and utilities identified chronic equipment and process losses, created a pillar-wise TPM roadmap, and set clear improvement targets for OEE, downtime, cost and yield across the value chain.

Consulting Services

Connect with our Experts!

With experience across diverse industries and challenges, we deliver unparalleled insights and solutions especially designed as per the needs. For more details, contact us today!

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