Appendix-I

Evaluation Questionnaire Sample

212
Appendix-II
TPM Internal Trainer Certificate Form

Evaluation Parameters:

1) Knowledge

2) Practical Experiece

3) Communication Skills

4) Presentation Skills

5) Confidence Level

6) Participation
Feedback

7) TPM Test

8) TPM Scorecard

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Appendix- III
Abnormality Card-Autonomous Maintenance

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Appendix- IV
Standard Operating Procedure Sheet

OPERATION NO. OPERATION NAME

No. Operation Description Main Steps Key Points Key Point

Sketch

PROTECTIVE JIGS/TOOLS REQUIRED TRAINING AUTHORISATION

CLOTHING REQUIRED CHECKS COMMENTS

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Appendix-V
5S Audit Form

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Appendix- VI
5S Red Tag

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Appendix- VII
Improvement (Kaizen) Record Sheet
Date : 1 Aug'10
Section : MRP CONTROL
IMPROVEMENT RECORD SHEET Deptt : MATERIALS
HARIDWAR Ref no :
Improvement Statement :
Please tick the relevant : ( )
Reducing Holding Time of Vehicle at Engine Supply Hub by capacity enhancement of 4 Docs by parking 4 vehicle to 6 vehicle in same
space, through extending Cemented doc, thereby eliminating pillar hinderance. P DETAILS OF BENEFIT
Q *Productivity increased
One Point Lesson / Control Plan ( if any): *Holding of vehicle reduced
C
from 1 hour to 15 mins
D *securing operation by
S
eliminating Gap b/w Doc and
vehicle
M
Status Before Improvement : Status After Improvement : Structure of Team Name Section
1. Pillar hinderance in Doc was making unsafe operation and thereb less 1. 6 vehicle can be parked in 4 doc at a time Team Leader : Anand Lal Agarwal MRP CONTROL

vehicle was parked at a time viz 4 vehicle in 4 Doc. 2. Gap between the Doc and Vehicle eliminated to safegauard Team Member : Balbir Singh Asst Stores
operation
Team Member : Sandeep kumar Asst Stores

Team Member :

PILLAR OBSTRUCTION F
PARKING 2 VEHICLE IN 2 DOC
BENEFITS :
Direct / Indirect
*Productivity increased
*Holding of vehicle reduced from 1 hour to 15 mins
*securing operation by eliminating Gap b/w Doc and
PLATFORM EXTENDEDTO FRONT vehicle
PARKING 2 VEHICLE IN 1 DOC

Root Cause Analysis: Counter Measure : Horizontal Deployment Opportunity : (Yes / No) NO
If Yes,
Where :
There was a improvement in design of doc, Cemented Doc was extended to reduce the Gap between the Doc
pillars were extended from doc level thereby hindering the parking of and the Vehicle, this created the space to park the vehicle.
How :
vehicle by creating gap between doc level and vehicle level.
Helper were unable to unload the material due to safety concern because
of gap created, hence less vehicle was parked at a time.

Who will do :

Target Date :

Team Leader Sign. Section Head Sign. Deptt Head Sign

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Appendix VIII
Questionnaire Survey Related Human Issues during
Implementation of Total Productive Maintenance

Instructions for filling the Questionnaire

1) Please answer the questions putting a tick mark (√) where (1) indicates poor (2)
indicates Average (3) indicates Good (4) indicates very Good (5) indicates Excellent
marks.
2) The questionnaire comprises of two sections. Section I deals with general background
of the organization. Section II seeks your opinion pertaining to various Human related
issues concerning Total Productive Maintenance.
3) There is no right or wrong answer. Please answer each question, which suits your
organization.

SECTION I

1) Name (optional)--------------------------------------
2) Designation/ Position-------------------------------
3) Name of the Organization ------------------------
4) Address-------------------------------------------------
5) Telephone--------------------------------------------------, Fax-------------------------------------
----------
6) Please specify type of organization:-
a) Automotive Industry b) Electronics and Electrical based Industry
c)Textiles Industry

d) Metals, Machinery Industry e)Plastics Industry f) Other if any---------------

-------

7) Year of Establishment -------------------------------------------------------------------------

---

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SECTION II

1) To what extent the Worker Assignment Strategies in your organization assign the
right job to the supervisor, Engineer, worker during implementation of TPM?

Poor, Average, Good, V Good, Excellent

2) To what extent the Skill Identification Approach helps to determine what types of
people to hire in your organization?

Poor, Average, Good, V Good, Excellent

3) To what extent Training plans and policies help for increasing productivity and quality
of your organization?

Poor, Average, Good, V Good, Excellent

4) To what extent Communication system (both oral and written) in your organization
play a vital role for successful implementation of TPM.

Poor, Average, Good, V Good, Excellent

5) To what extent Reward/Compensation scheme enhance productivity, job satisfaction

and organizational Performance in your organization?

Poor, Average, Good, V Good, Excellent

6) To what extent Teamwork in your organization helps to operate and control operations
in order to produce high quality products in a timely manner.

Poor, Average, Good, V Good, Excellent

7) To what extent the leadership quality in Senior Management actively encourage

change and implement a culture of trust in your organization?

Poor, Average, Good, V Good, Excellent

8) To what extent Employee Empowerment technique in your organization makes the

employees to do their work effectively?

Poor, Average, Good, V Good, Excellent

9) To what extent Employee Suggestion Scheme in your organization give logical and
practical suggestions for the improvement of the TPM?

Poor, Average, Good, V Good, Excellent

220
10) Does Employee flexibility and Multi skilling are actively used to support improved
performance in your organization?

Poor, Average, Good, V Good, Excellent

11) To what extent customer requirements are effectively disseminated and understood
throughout the workforce in Total Productive Maintenance to achieve customer
satisfaction in your organization?

Poor, Average, Good, V Good, Excellent

12) To what extent Motivation system improves quality excellence in TPM and decision
making in your organization ?

Poor, Average, Good, V Good, Excellent

13) To what extent the Employee’s loyalty and commitment of your organization and its
goals are effective in achieving improvement in quality?

Poor, Average, Good, V Good, Excellent

14) To what extent Environmental, health and safety practices of your organization
improves quality of work and products in TPM?

Poor, Average, Good, V Good, Excellent

THANKS FOR YOUR COOPERATION

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Appendix IX
5S Selected Interview Questions

Ques1.Which 5S activities you are following in the workplace?

Ques2. Do you think 5S activities are beneficial for the organization?

Ques3. Please elaborate have you given any suggestion or an improvement idea in some

process of your daily 5S activities?

Ques4. Do you need more training to effectively follow 5S activities?

Ques5. Please elaborate if you have been involved in any team work during your

employment in current organization and how you have contributed towards the team goals?

Ques6. Do you think that any improvement in communication due to the implementation of

5S concept?

Ques7. Do you think that reduction in a number of accidents and improvement in safety

measures after the successful implementation of 5S technique?

Ques8. Do you think that there was a significant improvement in confidence level and

morale because of 5S concept?

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Appendix X

One Point Lesson (OPL)

Internal - Confidential QM PILLAR 77

223
Appendix- XI
OPL and Team Members Training Data

224