https://www.maintwiz.com/tpm/jishu-hozen/https://www.maintwiz.com/wp-content/uploads/tpm/conveyor-drive-cil-points-numbered-drawing.webpThe conveyor drive from the worked example: step 1 tags the seal seep and missing guard bolt, step 2 adds the drip tray and remote grease point, step 3 writes a standard for all eight numbered points.The conveyor drive from the worked example: step 1 tags the seal seep and missing guard bolt, step 2 adds thehttps://www.maintwiz.com/wp-content/uploads/tpm/fuguai-efuda-red-white-tag-fields-gearbox-seal.webpFuguai tags (efuda) in Jishu Hozen: the red tag goes to maintenance, the white tag is closed by operators. Each carries a number, date, finder, equipment point, abnormality type and target date, and is entered in the register the same shift.Fuguai tags (efuda) in Jishu Hozen: the red tag goes to maintenance, the white tag is closed by operatorshttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-tag-records-assigned-closed-completed.webpThe Jishu Hozen dashboard in MaintWiz counts tag records by colour and by status, assigned, closed and completed, so the team leader sees open fuguai tags for each area without assembling a monthly report by hand.The Jishu Hozen dashboard in MaintWiz counts tag records by colour and by status, assigned, closed and https://www.maintwiz.com/tpm/5s-foundation/https://www.maintwiz.com/wp-content/uploads/tpm/ps-5s-audit-entry-zone-checks-and-score.webpA 5S audit in MaintWiz: the auditor scores each check for the zone, the total rolls up as the audit is saved, and a failed item can be raised in the abnormality register.A 5S audit in MaintWiz: the auditor scores each check for the zone, the total rolls up as the audit is saved,https://www.maintwiz.com/wp-content/uploads/tpm/ps-5s-dashboard-5s-radar.webpThe 5S radar in MaintWiz plots the average score of each S across audited zones; here standardise and sustain trail sort, so the plant's next audit cycle targets Seiketsu and Shitsuke.The 5S radar in MaintWiz plots the average score of each S across audited zones; here standardise and sustainhttps://www.maintwiz.com/wp-content/uploads/tpm/seiton-work-cell-plan-shadow-board-bins-lanes.webpSeiton in one work cell: a shadow board for every tool, bins with min and max marks, marked walkways, a red-tag holding area and a cleaning station, each numbered and visible from the aisle.Seiton in one work cell: a shadow board for every tool, bins with min and max marks, marked walkways, a https://www.maintwiz.com/what-is-oee/https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-equipment-loss-and-trend-by-day.webpEquipment E1 in July 2026: availability 99.48%, performance 83.85% and quality 100.00% multiply to OEE 83.41%, with the loss on each factor and a daily OEE calendar that shows non-running days.Equipment E1 in July 2026: availability 99.48%, performance 83.85% and quality 100.00% multiply to OEEhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-line-rollup-loss-and-trend.webpLine A roll-up of three equipment (E1 to E3) for July 2026: OEE 82.42% from availability 96.76%, performance 85.84% and quality 99.23%, weighted by planned time.Line A roll-up of three equipment (E1 to E3) for July 2026: OEE 82.42% from availability 96.76%, performance https://www.maintwiz.com/total-productive-maintenance/https://www.maintwiz.com/wp-content/uploads/tpm/efuda-tag-anatomy-fields.webpThe Efuda tag operators hang on equipment: red for maintenance and white for operators, each recording the tag number, date, equipment, fuguai type, finder and countermeasure until the abnormality is closed.The Efuda tag operators hang on equipment: red for maintenance and white for operators, each recording thehttps://www.maintwiz.com/wp-content/uploads/tpm/oee-six-big-losses-to-tpm-pillars-v2.webpEach of the six big losses has an owning pillar: breakdowns go to planned and autonomous maintenance, set-up and speed losses to focused improvement, defects to quality maintenance and start-up losses to focused improvement and early equipment management.Each of the six big losses has an owning pillar: breakdowns go to planned and autonomous maintenance, set-uphttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-tag-records-assigned-closed-completed.webpSoftware turns TPM routines into records: the MaintWiz Jishu Hozen dashboard counts every tag operators raise and tracks it through assigned, closed and completed, so managers see which abnormalities stay open.Software turns TPM routines into records: the MaintWiz Jishu Hozen dashboard counts every tag operators raise https://www.maintwiz.com/tpm/kobetsu-kaizen/https://www.maintwiz.com/wp-content/uploads/tpm/kobetsu-kaizen-a3-report-filled-labeller-v2.webpThe A3 project report on one page: theme and baseline on the left, analysis, countermeasures, results on the same definition and the updated standard on the right, filled with the labeller example (ILLUSTRATION).The A3 project report on one page: theme and baseline on the left, analysis, countermeasures, results on thehttps://www.maintwiz.com/wp-content/uploads/tpm/kobetsu-kaizen-loss-tree-calendar-time-to-theme.webpA loss tree walks calendar time down to valuable operating time through the 16 major losses, ranks the losses by equipment and stops at a theme one team can finish: here, minor stops on one labeller (ILLUSTRATION).A loss tree walks calendar time down to valuable operating time through the 16 major losses, ranks the losseshttps://www.maintwiz.com/wp-content/uploads/tpm/kobetsu-kaizen-worked-example-labeller-minor-stops.webpWorked example: minor stops on a labeller fall from 12 to 3 per shift once a worn roller is replaced, a roller-wear check enters the CIL standard and a one point lesson teaches tension setting (ILLUSTRATION).Worked example: minor stops on a labeller fall from 12 to 3 per shift once a worn roller is replaced, ahttps://www.maintwiz.com/wp-content/uploads/tpm/ps-cf-dashboard-kaizen-facility-department.webpKaizen analytics by facility and department show how many improvements are initiated, completed or cancelled, so the pillar owner sees where projects stall before the monthly review (MaintWiz).Kaizen analytics by facility and department show how many improvements are initiated, completed or cancelled,https://www.maintwiz.com/wp-content/uploads/tpm/ps-kaizen-idea-sheet-list-open-completed-cancelled.webpEach Kaizen idea sheet in MaintWiz carries a benchmark and a target for its area, and the list shows every idea by status, open, completed or cancelled, so the pillar owner sees what is moving (MaintWiz).Each Kaizen idea sheet in MaintWiz carries a benchmark and a target for its area, and the list shows everyhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-dashboard-lost-hours-pareto-cumulative-share.webpLost-hours Pareto for Line A in July 2026: speed losses from material and tooling plus sensor stops make up most of the lost time, so they head the project list (MaintWiz).Lost-hours Pareto for Line A in July 2026: speed losses from material and tooling plus sensor stops make up https://www.maintwiz.com/tpm/quality-maintenance/https://www.maintwiz.com/wp-content/uploads/tpm/hinshitsu-hozen-qa-matrix-defect-process-4m.webpThe QA matrix links each defect mode to the process step and equipment condition that produce it, grades the strength of each link and sets a standard value for the conditions that matter most (ILLUSTRATION).The QA matrix links each defect mode to the process step and equipment condition that produce it, grades thehttps://www.maintwiz.com/wp-content/uploads/tpm/hinshitsu-hozen-ten-steps-zero-defect-conditions.webpHinshitsu Hozen works in ten steps: restore conditions and remove fuguai, analyse which 4M conditions must hold to keep defects out, then set, check and review those conditions as standards.Hinshitsu Hozen works in ten steps: restore conditions and remove fuguai, analyse which 4M conditions musthttps://www.maintwiz.com/wp-content/uploads/tpm/ps-qd-matrix-report-defect-by-area.webpThe QD matrix report counts rejection records by phenomenon and area, so surface blemish on Line 1 and contamination at mixing stand out as the first rows for the quality maintenance matrix (MaintWiz).The QD matrix report counts rejection records by phenomenon and area, so surface blemish on Line 1 andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-qm-dashboard-rejection-rca-and-complaints.webpThe quality maintenance dashboard shows rejections by facility and defect phenomenon, rejection RCA compliance and customer complaints by status, the measures the Hinshitsu Hozen pillar owner reviews each month (MaintWiz).The quality maintenance dashboard shows rejections by facility and defect phenomenon, rejection RCAhttps://www.maintwiz.com/wp-content/uploads/tpm/quality-maintenance-die-clearance-to-burr-condition.webpQuality maintenance controls the condition, not the product: as punch-die clearance widens with wear the burr grows, so the standard sets a clearance limit and a check interval (ILLUSTRATION).Quality maintenance controls the condition, not the product: as punch-die clearance widens with wear the burr https://www.maintwiz.com/tpm/planned-maintenance/https://www.maintwiz.com/wp-content/uploads/tpm/jishu-hozen-keikaku-hozen-task-split.webpOperators take cleaning, inspection, lubrication and tightening through CIL standards, maintenance keeps periodic, condition and overhaul work, and tasks move across as operators pass Jishu Hozen steps 4 and 5.Operators take cleaning, inspection, lubrication and tightening through CIL standards, maintenance keepshttps://www.maintwiz.com/wp-content/uploads/tpm/keikaku-hozen-six-steps-jipm.webpThe planned maintenance (Keikaku Hozen) pillar is built in six steps: evaluate the equipment, restore deterioration, set up the information system, then periodic and predictive maintenance, and finally review the whole system.The planned maintenance (Keikaku Hozen) pillar is built in six steps: evaluate the equipment, restorehttps://www.maintwiz.com/wp-content/uploads/tpm/maintenance-types-trigger-matrix-planned-maintenance.webpCorrective work follows a failure, preventive work a calendar or counter, and predictive work a measured condition; the planned maintenance pillar chooses among them per equipment by criticality and failure history.Corrective work follows a failure, preventive work a calendar or counter, and predictive work a measuredhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-pm-dashboard-compliance-and-work-order-types.webpThe planned maintenance dashboard shows PM compliance, breakdown hours and work orders by type for the year, with compliance month by month, the measures the pillar is reviewed on (MaintWiz).The planned maintenance dashboard shows PM compliance, breakdown hours and work orders by type for the year,https://www.maintwiz.com/wp-content/uploads/tpm/ps-pm-schedule-form-trigger-frequency-upcoming.webpOne PM schedule for gearbox G-204 sets the trigger, the frequency and the next dates, with tasks, parts and people on their own tabs (MaintWiz).One PM schedule for gearbox G-204 sets the trigger, the frequency and the next dates, with tasks, parts andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-work-bench-planned-list-issue-summary-readable.webpThe work bench lists what is planned for a facility and date range, lets the planner revise planned dates and sends the work for approval, with the issue summary of each order on the same row (MaintWiz).The work bench lists what is planned for a facility and date range, lets the planner revise planned dates and https://www.maintwiz.com/tpm/early-equipment-management/https://www.maintwiz.com/wp-content/uploads/tpm/early-equipment-initial-flow-control-curve.webpDuring initial flow control every problem is logged and closed; handover happens when problems per week stay inside the agreed stable-operation band and standards, training and spares are in place, not on a fixed date (ILLUSTRATION).During initial flow control every problem is logged and closed; handover happens when problems per week stayhttps://www.maintwiz.com/wp-content/uploads/tpm/mp-design-before-after-lubrication-and-guard.webpA maintenance prevention design change: the grease point hidden behind a four-bolt guard moves to a remote lubrication block at the operator side, and the guard becomes hinged and interlocked.A maintenance prevention design change: the grease point hidden behind a four-bolt guard moves to a remotehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mp-sheet-completed-list.webpMP sheets are listed per facility and equipment by status and date, so a design review for a new filler can pull every lesson recorded on the fillers already running (MaintWiz).MP sheets are listed per facility and equipment by status and date, so a design review for a new filler canhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mp-sheet-necessity-classification-cause-target-standardization.webpAn MP sheet records the lesson in a form designers reuse: how necessary the feedback is, whether it concerns mechanism, control circuit, operation or raw material, the cause category and the target (MaintWiz).An MP sheet records the lesson in a form designers reuse: how necessary the feedback is, whether it concerns https://www.maintwiz.com/tpm/tpm-training-management/https://www.maintwiz.com/wp-content/uploads/tpm/ps-et-dashboard-training-sessions-and-attendance.webpThe education and training dashboard counts sessions, completed training hours, people trained and attendance by role, the measures the Kyoiku Kunren pillar is reviewed on each month (MaintWiz).The education and training dashboard counts sessions, completed training hours, people trained and attendancehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-training-sessions-list-enrollment-tabs.webpTraining sessions are planned, enrolled and completed from one list, each with dates, trainer and the skill it builds, such as autonomous maintenance step 2, lockout or OPL writing (MaintWiz).Training sessions are planned, enrolled and completed from one list, each with dates, trainer and the skillhttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-skills-matrix-quarter-circle-levels.webpA skills matrix shows who can do what: each quarter of the circle is one level, from learning to teaches others, and the gaps against the target set the next training sessions (ILLUSTRATION).A skills matrix shows who can do what: each quarter of the circle is one level, from learning to teaches https://www.maintwiz.com/tpm/enterprise-safety-management/https://www.maintwiz.com/wp-content/uploads/tpm/lockout-tagout-isolation-points-conveyor-drive.webpBefore work under a permit, each energy source on the conveyor drive is isolated, locked and tagged with the permit number: main isolator, local stop, pneumatic supply and stored energy, then tested (ILLUSTRATION).Before work under a permit, each energy source on the conveyor drive is isolated, locked and tagged with thehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-eptw-permit-form-general-risk-ppe.webpThe permit form carries the work, the permit types, the contractor and the emergency contact, with the risk analysis and PPE on their own tabs (MaintWiz).The permit form carries the work, the permit types, the contractor and the emergency contact, with the riskhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-eptw-permit-list-status-tabs.webpSafety permits move through eight statuses, from saved and waiting for approval to approved, closed, cancelled or rejected, with the permit type, times and work description on each row (MaintWiz).Safety permits move through eight statuses, from saved and waiting for approval to approved, closed,https://www.maintwiz.com/wp-content/uploads/tpm/ps-near-miss-register-list-severity-and-occurrence.webpNear misses from safety walks are logged with location, severity potential and occurrence date, then assigned and closed, so leading indicators are counted before an incident happens (MaintWiz).Near misses from safety walks are logged with location, severity potential and occurrence date, then assignedhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-opl-record-form-classification-pillar-steps.webpA safety one point lesson for lockout before a filter change: classification, SHE pillar, the lesson in one sentence, the step with its picture, and initiator, verifier and approver (MaintWiz).A safety one point lesson for lockout before a filter change: classification, SHE pillar, the lesson in onehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-she-dashboard-incident-reporting-compliance.webpThe SHE dashboard puts lagging measures (incidents, lost-time cases) beside leading ones (reporting within 24 hours, BBSO observations, near misses) by category, facility and body part (MaintWiz).The SHE dashboard puts lagging measures (incidents, lost-time cases) beside leading ones (reporting within 24 https://www.maintwiz.com/tpm/office-tpm/https://www.maintwiz.com/wp-content/uploads/tpm/ps-action-items-and-meetings-tracker.webpMeeting actions are tracked to closure for daily and weekly TPM reviews, with the original and the revised target date side by side in the same system as the shop-floor pillars (MaintWiz).Meeting actions are tracked to closure for daily and weekly TPM reviews, with the original and the revisedhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-otpm-abnormality-list-status-tabs.webpOffice abnormalities are raised, assigned and closed in the same way as plant tags, with open, completed, closed and cancelled lists so a stalled request is visible by office location (MaintWiz).Office abnormalities are raised, assigned and closed in the same way as plant tags, with open, completed,https://www.maintwiz.com/wp-content/uploads/tpm/ps-otpm-dashboard-red-white-tag-records.webpThe office TPM dashboard counts red and white tag records by status, assigned, closed and completed, so the office pillar sees how many losses are still open in each period (MaintWiz).The office TPM dashboard counts red and white tag records by status, assigned, closed and completed, so the https://www.maintwiz.com/importance-of-one-point-lesson/https://www.maintwiz.com/wp-content/uploads/tpm/opl-examples-basic-trouble-improvement.webpThe three kinds of one point lesson: basic knowledge on chain tension with a go/no-go gauge, a problem case on a guard bolt that backed out, and an improvement case replacing four screws with one fastener.The three kinds of one point lesson: basic knowledge on chain tension with a go/no-go gauge, a problem casehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-opl-completed-records-list.webpOne point lessons are listed by equipment, theme, classification and approver, with open, completed and cancelled tabs and a PDF of each lesson for display at the machine (MaintWiz).One point lessons are listed by equipment, theme, classification and approver, with open, completed andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-opl-record-form-classification-pillar-steps.webpThe OPL record form holds the classification, the pillar, the theme, the lesson and its numbered steps with pictures, ready for the initiator, verifier and approver to sign off (MaintWiz).The OPL record form holds the classification, the pillar, the theme, the lesson and its numbered steps withhttps://www.maintwiz.com/wp-content/uploads/tpm/tpl-preview-opl-print-form-v3.webpThe OPL print template: OPL number, equipment and pillar, one theme of about 70 characters, before and correct pictures, short steps with the reason for each, PPE, verification and three sign-offs.The OPL print template: OPL number, equipment and pillar, one theme of about 70 characters, before and https://www.maintwiz.com/tpm/ai-oee-overall-equipment-effectiveness/https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-capacity-master-per-hour-and-cycle-time-v2.webpMaster data first: the MaintWiz capacity master holds units per hour and cycle time for each product on each equipment, which sets the ideal rate behind every performance figure on the dashboards above.Master data first: the MaintWiz capacity master holds units per hour and cycle time for each product on eachhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-downtime-report-summary.webpOne month of coded stops in the MaintWiz downtime report: 183.3 lost hours from 187 events, split into unplanned 19.3 h, planned 15.7 h and performance loss 148.3 h, with reduced speed and minor stoppage the largest categories.One month of coded stops in the MaintWiz downtime report: 183.3 lost hours from 187 events, split intohttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-equipment-loss-and-trend-by-day.webpEquipment view for July 2026: OEE 83.41% from availability 99.48%, performance 83.85% and quality 100.00%, where performance carries 16.07 of the 16.59-point loss, with the daily OEE calendar below.Equipment view for July 2026: OEE 83.41% from availability 99.48%, performance 83.85% and quality 100.00%,https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-line-rollup-loss-and-trend.webpLine A roll-up of three equipment (E1 to E3) for July 2026: OEE 82.42% from availability 96.76%, performance 85.84% and quality 99.23%, weighted by planned time.Line A roll-up of three equipment (E1 to E3) for July 2026: OEE 82.42% from availability 96.76%, performancehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-lost-hours-pareto-and-oee-by-month-v2.webpLost hours Pareto and OEE by month for one line: the two reduced-speed reasons lead the Pareto with 48.6% of 183.3 hours, beside the monthly OEE trend for Line A, July 2025 to July 2026.Lost hours Pareto and OEE by month for one line: the two reduced-speed reasons lead the Pareto with 48.6% ofhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-plant-rollup-loss-and-trend.webpPlant A roll-up of six equipment (E1 to E6) on three lines: OEE 81.39% from availability 95.64%, performance 86.42% and quality 98.47%, weighted by planned time.Plant A roll-up of six equipment (E1 to E6) on three lines: OEE 81.39% from availability 95.64%, performancehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-production-log-entry-form-stop-reason-code.webpProduction entry in the MaintWiz OEE module: each shift's output, stops with reason codes and counts are captured against the equipment, using the loss codes and capacities set up for your plant.Production entry in the MaintWiz OEE module: each shift's output, stops with reason codes and counts arehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-production-log-entry-list-oee-per-shift-v2.webpEvery shift's OEE comes from its production log entry: actual and ideal minutes, availability, performance and quality are kept for each entry, so the daily figure can be traced back to the stops and counts behind it.Every shift's OEE comes from its production log entry: actual and ideal minutes, availability, performance https://www.maintwiz.com/tpm/tpm-digital-transformation/https://www.maintwiz.com/wp-content/uploads/tpm/iot-condition-monitoring-motor-sensor-points-to-work-order.webpFour sensor points on a conveyor drive, bearing vibration at both ends, winding temperature and motor current, feed MaintWiz condition monitoring, and a reading past its limit raises a work order automatically.Four sensor points on a conveyor drive, bearing vibration at both ends, winding temperature and motorhttps://www.maintwiz.com/wp-content/uploads/tpm/mobile-capture-phone-screens-tag-flow-v2.webpA tag moves from the machine to a work order in three phone steps: the operator raises it with colour and photo, the owner reviews it, and maintenance converts it into a planned job.A tag moves from the machine to a work order in three phone steps: the operator raises it with colour andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mobile-capture-tag-5s-audit-work-order-phones.webpOperators capture on a phone: an Efuda tag with colour and photo, the saved tag converted to a work order, a five-row 5S audit with its score, and a quick work order with down time.Operators capture on a phone: an Efuda tag with colour and photo, the saved tag converted to a work order, ahttps://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-central-goals-events-repository.webpA digital programme keeps its goals, events and documents in one place: TPM Central in MaintWiz shows goals against actuals, the event calendar and the document repository for every pillar.A digital programme keeps its goals, events and documents in one place: TPM Central in MaintWiz shows goalshttps://www.maintwiz.com/wp-content/uploads/tpm/tpl-preview-tpm-activity-board-a3-v3.webpA digital TPM activity board carries the same panels as the wall board: pillar policy, PQCDSM targets, the OEE trend, the Jishu Hozen step ladder and open actions, refreshed from the records instead of by hand.A digital TPM activity board carries the same panels as the wall board: pillar policy, PQCDSM targets, the https://www.maintwiz.com/tpm/tpm-implementation/https://www.maintwiz.com/wp-content/uploads/tpm/ps-equipment-register-list-criticality-and-class.webpThe roll-out starts from the equipment list in MaintWiz: criticality, class and next schedule date for each asset show which high-criticality line becomes the pilot and which assets follow in the rollout.The roll-out starts from the equipment list in MaintWiz: criticality, class and next schedule date for eachhttps://www.maintwiz.com/wp-content/uploads/tpm/tpl-preview-am-step-audit-sheet.webpThe Jishu Hozen step audit sheet scores each autonomous maintenance step against fixed items, and a team moves to the next of the seven steps only after passing; the sheet is a free download.The Jishu Hozen step audit sheet scores each autonomous maintenance step against fixed items, and a teamhttps://www.maintwiz.com/wp-content/uploads/tpm/tpl-preview-tpm-master-plan-gantt.webpILLUSTRATION. The master plan sets an owner, start and finish dates and progress for each of the 12 steps, so the steering committee reviews one Gantt each month; the tracker is a free Excel download.ILLUSTRATION https://www.maintwiz.com/best-cmms-for-total-productive-maintenance-tpm/https://www.maintwiz.com/wp-content/uploads/tpm/ps-cf-dashboard-poka-yoke-mp-sheet.webpThe same CMMS counts poka-yoke devices and MP sheets by facility, so Kobetsu Kaizen and early equipment management sit in one AI CMMS with the work orders they create (MaintWiz).The same CMMS counts poka-yoke devices and MP sheets by facility, so Kobetsu Kaizen and early equipmenthttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jishu-hozen-abnormality-register-form.webpThe operator side of a CMMS for TPM: an efuda tag is recorded against the machine with its tag colour, nature of issue, assignee and findings, ready to convert to a work order (MaintWiz).The operator side of a CMMS for TPM: an efuda tag is recorded against the machine with its tag colour, naturehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-quick-work-order-form-downtime-and-issue.webpA quick work order closes a capper misfeed: 2.5 hours of down time, the issue and failure codes and the cleaning done are saved on one form and feed the loss Pareto (MaintWiz).A quick work order closes a capper misfeed: 2.5 hours of down time, the issue and failure codes and thehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-work-order-list-status-tabs.webpThe MaintWiz work order list splits open, completed, closed, approved and safety work orders into tabs, with owner, type, line and equipment on each row for breakdown, preventive and inspection jobs (MaintWiz).The MaintWiz work order list splits open, completed, closed, approved and safety work orders into tabs, with https://www.maintwiz.com/how-to-improve-your-oee-with-tpm/https://www.maintwiz.com/wp-content/uploads/tpm/oee-six-big-losses-to-tpm-pillars-v2.webpEach of the six big losses has an owning pillar: Jishu Hozen and planned maintenance for breakdowns, Kobetsu Kaizen for setup, minor stops and speed, quality maintenance and early equipment management for defects and start-up.Each of the six big losses has an owning pillar: Jishu Hozen and planned maintenance for breakdowns, Kobetsuhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-lost-hours-pareto-and-oee-by-month.webpRank, then verify: the lost-hours Pareto puts the two reduced-speed reasons first, and the monthly OEE trend for Line A shows whether the work on them moves OEE, here from 78.9% to 83.9%.Rank, then verify: the lost-hours Pareto puts the two reduced-speed reasons first, and the monthly OEE trend https://www.maintwiz.com/total-productive-maintenance-tpm-fundamentals/https://www.maintwiz.com/wp-content/uploads/tpm/ps-opl-record-form-classification-pillar-steps.webpA one point lesson (OPL) in MaintWiz: each lesson is classed as basic knowledge, a problem case or an improvement, tied to its pillar, and written as short numbered steps an operator learns in minutes.A one point lesson (OPL) in MaintWiz: each lesson is classed as basic knowledge, a problem case or an https://www.maintwiz.com/tpm/https://www.maintwiz.com/wp-content/uploads/tpm/ps-jishu-hozen-abnormality-register-form.webpA Jishu Hozen tag in MaintWiz: the operator records equipment, tag colour, fuguai type and a photo, and the tag moves through assigned, closed and completed, or becomes a work order after review.A Jishu Hozen tag in MaintWiz: the operator records equipment, tag colour, fuguai type and a photo, and thehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-my-workspace-orders-and-shortcuts.webpThe MaintWiz workspace for a maintenance technician: open work, service and calibration orders, work requests, meter readings and condition monitoring, with shortcuts to action items, shift handover and CAPA monitoring.The MaintWiz workspace for a maintenance technician: open work, service and calibration orders, workhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-pm-schedule-form-trigger-frequency-upcoming.webpA Keikaku Hozen schedule in MaintWiz: each PM runs on a time, condition or event trigger with a fixed, floating or daily frequency, and the next twelve dates are listed before the work orders are raised.A Keikaku Hozen schedule in MaintWiz: each PM runs on a time, condition or event trigger with a fixed,https://www.maintwiz.com/wp-content/uploads/tpm/ps-production-log-entry-list-oee-per-shift.webpOEE is captured shift by shift in MaintWiz: each production log entry records output, rejects and losses against the product's rated capacity, and the module computes availability, performance and quality for the line.OEE is captured shift by shift in MaintWiz: each production log entry records output, rejects and losseshttps://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-central-goals-events-repository.webpGoals, events and documents for the whole programme on one page: TPM Central in MaintWiz shows goals against actuals, the event calendar and the document repository behind the TPM management system.Goals, events and documents for the whole programme on one page: TPM Central in MaintWiz shows goals againsthttps://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-dashboard-eight-pillars.webpThe MaintWiz TPM programme view: line OEE with availability, performance and quality, the 5S audit trend across 64 zones, and one tile per pillar from Jishu Hozen tags to office TPM tags.The MaintWiz TPM programme view: line OEE with availability, performance and quality, the 5S audit trendhttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-dashboard-collage-web-tablet-mobile-v2.webpOne set of records on three screens: the programme dashboard on a laptop, the Jishu Hozen red and white tag records on a tablet, and raising a tag on a phone at the machine.One set of records on three screens: the programme dashboard on a laptop, the Jishu Hozen red and white taghttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-pillars-and-maintwiz-modules-v2.webpEach TPM pillar and the MaintWiz module that holds its records: Jishu Hozen in the abnormality register, Keikaku Hozen in PM scheduling, Kobetsu Kaizen in the KK pillar, Shoki Kanri in MP sheets, on a 5S base.Each TPM pillar and the MaintWiz module that holds its records: Jishu Hozen in the abnormality register, https://www.maintwiz.com/tpm/tpm-pillars/https://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-dashboard-eight-pillars.webpOne programme view holds all eight pillars: Jishu Hozen tags, PM work orders, Kaizen records, quality RCA, training, near misses, MP sheets and office tags, with OEE and the 5S audit trend alongside.One programme view holds all eight pillars: Jishu Hozen tags, PM work orders, Kaizen records, quality RCA,https://www.maintwiz.com/wp-content/uploads/tpm/tpm-eight-pillars-jipm-house-tiers-japanese-names.webpThe eight pillars of Total Productive Maintenance in JIPM's three tiers: four core pillars cut losses, two necessary pillars support them and two optional pillars extend the system, all standing on Seiri, Seiton, Seiso, Seiketsu and Shitsuke.The eight pillars of Total Productive Maintenance in JIPM's three tiers: four core pillars cut losses, twohttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-pillar-records-in-maintwiz-eight-screens.webpEach pillar leaves one working record: an Efuda tag for Jishu Hozen, a Kaizen sheet for Kobetsu Kaizen, a PM schedule for Keikaku Hozen, and five more, each held on its own MaintWiz screen.Each pillar leaves one working record: an Efuda tag for Jishu Hozen, a Kaizen sheet for Kobetsu Kaizen, a PMhttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-pillars-working-together-tag-to-project-to-lesson.webpThe pillars share records: a Jishu Hozen tag becomes a planned maintenance work order, a repeat loss becomes a Kobetsu Kaizen project, and the lesson becomes a one point lesson and an updated CIL standard.The pillars share records: a Jishu Hozen tag becomes a planned maintenance work order, a repeat loss becomes https://www.maintwiz.com/tpm/six-big-losses/https://www.maintwiz.com/wp-content/uploads/tpm/jipm-16-major-losses-three-groups-v2.webpThe JIPM 16 major losses: eight equipment losses, five manpower losses and three resource losses. The six filled boxes are the six big losses behind OEE; tool change and scheduled shutdown sit outside them.The JIPM 16 major losses: eight equipment losses, five manpower losses and three resource losseshttps://www.maintwiz.com/wp-content/uploads/tpm/oee-six-big-losses-to-tpm-pillars-v2.webpWhich pillar removes which of the six big losses: Jishu Hozen and planned maintenance take breakdowns, Kobetsu Kaizen takes setup, minor stops and speed, and quality maintenance with early equipment management takes defects and start-up rejects.Which pillar removes which of the six big losses: Jishu Hozen and planned maintenance take breakdowns,https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-dashboard-lost-hours-pareto-v2.webpLine A, July 2026: 183.3 lost hours ranked by reason. Two reduced-speed reasons, material and tooling, make up 48.6% of the total, so they are the first focused improvement projects.Line A, July 2026: 183.3 lost hours ranked by reasonhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-loss-cost-matrix-fixed-costs-v2.webpThe MaintWiz loss cost master holds direct and indirect manpower, utilities and depreciation for each loss on each equipment, so lost hours from the Pareto convert straight into a cost per lost hour.The MaintWiz loss cost master holds direct and indirect manpower, utilities and depreciation for each loss on https://www.maintwiz.com/tpm/autonomous-maintenance-checklist/https://www.maintwiz.com/wp-content/uploads/tpm/daily-am-checklist-conveyor-drive-shift-sheet.webpILLUSTRATION. A daily Jishu Hozen check sheet for the conveyor drive: eight numbered points, one line each, OK or NG per shift, and the tag number written wherever a check fails.ILLUSTRATIONhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mobile-capture-tag-5s-audit-work-order-phones.webpOperators raise what the shift check finds on a phone in MaintWiz: a failed point becomes an abnormality tag with photo, equipment and colour, the saved tag converts to a work order, and the same app takes 5S audits and quick work orders.Operators raise what the shift check finds on a phone in MaintWiz: a failed point becomes an abnormality taghttps://www.maintwiz.com/wp-content/uploads/tpm/tpl-preview-cil-standard-print-form-filled.webpILLUSTRATION. The CIL standard print form: the numbered drawing at the top left matches the rows, and each row gives the task, what good looks like, the tool or lubricant, minutes and frequency.ILLUSTRATION https://www.maintwiz.com/tpm/oee-calculator/https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-capacity-master-per-hour-and-cycle-time-v2.webpThe ideal rate comes from the MaintWiz capacity master: units per hour and cycle time for each product on each equipment, the design or best demonstrated rate and never last month's average.The ideal rate comes from the MaintWiz capacity master: units per hour and cycle time for each product onhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-equipment-loss-and-trend-by-day.webpThe same factors from continuous capture: equipment E1 for July 2026, with availability 99.48%, performance 83.85%, quality 100% and OEE 83.41%, calculated from the shift logs (MaintWiz OEE dashboard).The same factors from continuous capture: equipment E1 for July 2026, with availability 99.48%, performancehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-production-log-entry-list-oee-per-shift-v2.webpThe MaintWiz production log keeps the calculator's working for every shift: actual and ideal minutes, availability, performance, quality and the OEE that shift produced, so the hand check becomes a daily record.The MaintWiz production log keeps the calculator's working for every shift: actual and ideal minutes, https://www.maintwiz.com/tpm/tpm-metrics-kpis/https://www.maintwiz.com/wp-content/uploads/tpm/mtbf-mttr-worked-example-timeline.webpWorked example: a machine scheduled 720 hours fails four times with 10 repair hours, so operating time is 710 hours, MTBF is 177.5 hours, MTTR is 2.5 hours and inherent availability is 98.6 percent.Worked example: a machine scheduled 720 hours fails four times with 10 repair hours, so operating time is 710https://www.maintwiz.com/wp-content/uploads/tpm/ps-equipment-health-card-work-orders-and-pm.webpThe MaintWiz Equipment Health Card for one gearbox: six breakdowns and 38.5 hours lost over six months give an MTTR of about 6.4 hours, beside work orders by issue and monthly PM checklist compliance.The MaintWiz Equipment Health Card for one gearbox: six breakdowns and 38.5 hours lost over six months givehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-kpi-breakdown-occurrence-and-hours-by-month-and-day.webpMaintWiz breakdown KPIs: occurrence falls from 62 to 39 a month and hours lost from 124 to 84 over twelve months, with a daily view of the latest month to spot repeat days.MaintWiz breakdown KPIs: occurrence falls from 62 to 39 a month and hours lost from 124 to 84 over twelvehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-kpi-overview-by-pillar.webpOne MaintWiz screen holds the pillar KPIs: tags closed against raised, PM compliance, OEE as availability times performance times quality, RCA compliance, training hours and 5S compliance, with line OEE by month underneath.One MaintWiz screen holds the pillar KPIs: tags closed against raised, PM compliance, OEE as availability https://www.maintwiz.com/tpm/tpm-vs-rcm/https://www.maintwiz.com/wp-content/uploads/tpm/ps-pm-schedule-form-trigger-frequency-upcoming.webpWhere RCM output lands: each selected task becomes a MaintWiz PM schedule with a time, condition or event trigger, a fixed or floating frequency and a list of upcoming due dates, ready for work orders.Where RCM output lands: each selected task becomes a MaintWiz PM schedule with a time, condition or eventhttps://www.maintwiz.com/wp-content/uploads/tpm/rcm-six-failure-patterns-a-to-f.webpThe six failure patterns behind RCM: only the bathtub, wear-out and gradual-rise curves reward replacement at a fixed age, so RCM asks whether a task is worth doing before it enters the planned maintenance schedule.The six failure patterns behind RCM: only the bathtub, wear-out and gradual-rise curves reward replacement at https://www.maintwiz.com/tpm/tpm-self-assessment/https://www.maintwiz.com/wp-content/uploads/tpm/ps-5s-dashboard-compliance-and-month-wise.webpAfter the self-assessment, basic conditions become a monthly 5S audit in MaintWiz: compliance by zone and the month-wise score show whether the lowest-scoring area is moving up before the next quarterly re-score.After the self-assessment, basic conditions become a monthly 5S audit in MaintWiz: compliance by zone and thehttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-self-assessment-result-radar-twelve-areas.webpILLUSTRATION. A plant averaging 2.1 lands in the Defined band; its three lowest areas, loss definitions, autonomous maintenance and early equipment management, become the first work and map to MaintWiz modules.ILLUSTRATION https://www.maintwiz.com/tpm/tpm-excellence-award/https://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-central-goals-events-repository.webpThe MaintWiz TPM central repository keeps goals, events and pillar records in one place, so a site can show JIPM assessors step audits, tag closure and Kaizen results by pillar and date without collecting paper.The MaintWiz TPM central repository keeps goals, events and pillar records in one place, so a site can show https://www.maintwiz.com/tpm/tpm-templates-and-tools/https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-line-rollup-loss-and-trend.webpThe MaintWiz OEE module rolls equipment up to line and plant by planned time, with loss bars and a daily OEE calendar, so the OEE workbook's roll-up sheet becomes a live view of every line.The MaintWiz OEE module rolls equipment up to line and plant by planned time, with loss bars and a daily OEEhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-training-sessions-list-enrollment-tabs.webpThe MaintWiz training module lists sessions by enrollment status with dates, trainer and skill, so the skills matrix and training plan workbook becomes one record per session and person.The MaintWiz training module lists sessions by enrollment status with dates, trainer and skill, so the skillshttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-templates-paper-to-maintwiz-screens.webpThree free templates beside the MaintWiz screens that replace them: the one point lesson form and OPL list, the tag register and abnormality register, and the 5S audit form and 5S radar dashboard.Three free templates beside the MaintWiz screens that replace them: the one point lesson form and OPL list,https://www.maintwiz.com/wp-content/uploads/tpm/tpm-templates-six-sheet-previews-v3.webpSix of the free files as they open: the Kobetsu Kaizen A3 report, the CIL standards sheet, the Jishu Hozen step audit, the red and white tag register, the downtime reason-code library and the 5S audit form.Six of the free files as they open: the Kobetsu Kaizen A3 report, the CIL standards sheet, the Jishu Hozen https://www.maintwiz.com/tpm/red-tag-system/https://www.maintwiz.com/wp-content/uploads/tpm/5s-red-tag-vs-tpm-fuguai-tag-fields.webpTwo different red tags: the 5S red tag marks an item that may not be needed in the area, the TPM fuguai red tag marks an abnormality on equipment that maintenance must fix. Fields and owners differ.Two different red tags: the 5S red tag marks an item that may not be needed in the area, the TPM fuguai redhttps://www.maintwiz.com/wp-content/uploads/tpm/fuguai-efuda-red-white-tag-fields-gearbox-seal.webpWhat goes on the tag: number, date, finder, equipment point, abnormality type, description and target date. The same fields are typed into the register so the tag and the record always match.What goes on the tag: number, date, finder, equipment point, abnormality type, description and target datehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-day-wise-tag-closure.webpDay-wise tag closure in MaintWiz: tags raised against tags closed each day, the measure that shows whether the tag system keeps up or a backlog is building.Day-wise tag closure in MaintWiz: tags raised against tags closed each day, the measure that shows whetherhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jishu-hozen-abnormality-register-form.webpA red tag register entry in MaintWiz: ABN number, facility and equipment, status, person assigned, start and end time, nature of issue, the abnormality found and the fuguai tag colour, all on one form.A red tag register entry in MaintWiz: ABN number, facility and equipment, status, person assigned, start andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jishu-hozen-dashboard-red-white-tag-records.webpThe Jishu Hozen dashboard in MaintWiz splits red, white and yellow tag records into assigned, closed and completed and shows cumulative closure by colour, so a growing open pile is visible every week.The Jishu Hozen dashboard in MaintWiz splits red, white and yellow tag records into assigned, closed and https://www.maintwiz.com/product/autonomous-maintenance-software/https://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-contamination-and-hard-to-access.webpSources of contamination and hard-to-access places, the targets of Jishu Hozen step 2, each tracked as assigned, closed and completed records: 233 contamination and 121 hard-to-access records completed in the period.Sources of contamination and hard-to-access places, the targets of Jishu Hozen step 2, each tracked ashttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-day-wise-tag-closure.webpDay-wise tag closure records by colour, red, white and yellow, from 21 September to 22 October: between 13 and 18 tags close on each reporting day, so a drop in closures shows within the week.Day-wise tag closure records by colour, red, white and yellow, from 21 September to 22 October: between 13https://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-facility-pareto-and-monthly-change.webpAbnormalities by facility as a Pareto, Production Hall 1 highest at 468, and month-on-month change in abnormalities found, from 148 in November 2025 to a peak of 258 in August 2026.Abnormalities by facility as a Pareto, Production Hall 1 highest at 468, and month-on-month change inhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-tag-records-assigned-closed-completed.webpThe Jishu Hozen abnormality dashboard counts 2,412 tags: 1,086 red, 1,148 white and 178 yellow, with red and white tag records split into assigned, closed and completed, so open work by tag colour is visible.The Jishu Hozen abnormality dashboard counts 2,412 tags: 1,086 red, 1,148 white and 178 yellow, with red andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mobile-jh-operator-own-area-overdue-phone.webpOn the operator's phone, the own-area list shows the open tags on Filling Line A, with overdue items flagged by days past target, so each shift starts with the tags it must close.On the operator's phone, the own-area list shows the open tags on Filling Line A, with overdue items flaggedhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-tablet-jh-cil-check-raises-tag.webpAt Filler Unit F-3 the operator finds a fault during the cleaning and inspection round and raises it as an abnormality tag on a tablet, with tag colour and type, against the same equipment, so it reaches the register with an owner.At Filler Unit F-3 the operator finds a fault during the cleaning and inspection round and raises it as an https://www.maintwiz.com/product/abnormality-management-software/https://www.maintwiz.com/wp-content/uploads/tpm/mobile-capture-phone-screens-tag-flow-v2.webpRaising a tag at the Gemba on a phone: the operator picks the equipment, the tag colour and the abnormality type, adds a photo and saves; the record reaches the register with an ABN number and an owner.Raising a tag at the Gemba on a phone: the operator picks the equipment, the tag colour and the abnormalityhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-abnormality-overdue-alerts-own-area.webpThe operator's own-area view lists open tags on Packing Line 1, with three items flagged overdue by days past their target date, so the shift can close them before the Jishu Hozen review.The operator's own-area view lists open tags on Packing Line 1, with three items flagged overdue by days pasthttps://www.maintwiz.com/wp-content/uploads/tpm/ps-abnormality-register-list-status-tabs-tag-letters.webpThe abnormality register opens on the Open tab with 403 tags, each with ABN number, owner, equipment, tag colour and target date; Closed, Completed, Auditee Work Completed, Cancelled and Non-Conformance Records are one click away.The abnormality register opens on the Open tab with 403 tags, each with ABN number, owner, equipment, taghttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jishu-hozen-abnormality-countermeasure-documents.webpThe countermeasure section closes the loop: cause of abnormality (worn seal, blocked breather), the countermeasure, a breather check added to the weekly CIL standard, and the photo, work order and updated standard attached to the record.The countermeasure section closes the loop: cause of abnormality (worn seal, blocked breather), thehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jishu-hozen-abnormality-register-form-completed.webpThe abnormality form records the fuguai found, oil seeping at the gearbox output shaft seal, against Gearbox Drive G-204 with a red tag, nature of issue, the person assigned and the time taken to contain it.The abnormality form records the fuguai found, oil seeping at the gearbox output shaft seal, against Gearboxhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-otpm-dashboard-red-white-tag-records.webpOffice TPM uses the same abnormality register with its own dashboard: red and white tags raised in office areas, counted as pending, completed, closed and cancelled.Office TPM uses the same abnormality register with its own dashboard: red and white tags raised in office https://www.maintwiz.com/product/5s-audit-software/https://www.maintwiz.com/wp-content/uploads/tpm/ps-5s-audit-entry-zone-checks-and-score-v2.webpOne zone audit, Packing Line 2: ten checks under Seiri, Seiton, Seiso, Seiketsu and Shitsuke, each with the auditor's observation and a 0 to 4 score, totalled to 31 of 40, or 77.5%.One zone audit, Packing Line 2: ten checks under Seiri, Seiton, Seiso, Seiketsu and Shitsuke, each with thehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-5s-audit-list-status-tabs-score.webpThe 5S audit list moves each zone audit through Open, Audit Completed, Auditee Work Completed, Closed and Cancelled, with score and percentage beside the zone, so open follow-up work stays visible.The 5S audit list moves each zone audit through Open, Audit Completed, Auditee Work Completed, Closed andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-5s-dashboard-5s-radar-japanese-terms.webpThe 5S radar averages audit scores by S across all zones: Seiri (Sort) 84, Seiton (Set in order) 77, Seiso (Shine) 73, Seiketsu (Standardise) 69 and Shitsuke (Sustain) 70, so Standardise is weakest.The 5S radar averages audit scores by S across all zones: Seiri (Sort) 84, Seiton (Set in order) 77, Seisohttps://www.maintwiz.com/wp-content/uploads/tpm/ps-5s-dashboard-compliance-and-month-wise.webpThe MaintWiz 5S dashboard shows plant compliance of 74.60% across 64 zones, the highest zone at 96.20 and the lowest at 38.50, with month-wise compliance rising from 68% to 82% over twelve months.The MaintWiz 5S dashboard shows plant compliance of 74.60% across 64 zones, the highest zone at 96.20 and thehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-5s-dashboard-top-and-low-10-zones.webpTop and low 10 zones in the 5S dashboard: Production Hall 1 leads at 96.2 while Workshop Area A trails at 38.5, so audit effort and follow-up actions go to the low ten first.Top and low 10 zones in the 5S dashboard: Production Hall 1 leads at 96.2 while Workshop Area A trails athttps://www.maintwiz.com/wp-content/uploads/tpm/ps-5s-finding-raised-in-abnormality-register.webpA Seiketsu (Standardise) finding from audit 5ST-2026-1462 on Packing Line 2, gauge ranges unmarked, raised in the abnormality register with a yellow tag, the line supervisor as owner and a target date.A Seiketsu (Standardise) finding from audit 5ST-2026-1462 on Packing Line 2, gauge ranges unmarked, raised inhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mobile-5s-audit-zone-score-phone.webpThe 5S audit on a phone: the auditor picks the zone, scores Seiri, Seiton, Seiso, Seiketsu and Shitsuke at the Gemba, adds a photo of each finding and saves; the percentage totals as scores are entered.The 5S audit on a phone: the auditor picks the zone, scores Seiri, Seiton, Seiso, Seiketsu and Shitsuke at https://www.maintwiz.com/product/one-point-lesson-software/https://www.maintwiz.com/wp-content/uploads/tpm/ps-cf-dashboard-opl-facility-pillar.webp412 one point lessons in twelve months, by facility and by pillar: autonomous maintenance (Jishu Hozen) 148, planned maintenance 96, SHE 62, quality 54, Kobetsu Kaizen 32 and early equipment management 20.412 one point lessons in twelve months, by facility and by pillar: autonomous maintenance (Jishu Hozen) 148,https://www.maintwiz.com/wp-content/uploads/tpm/ps-opl-completed-records-list.webpCompleted one point lessons for twelve months, each tied to equipment with its theme and OPL type, Basic Knowledge, Trouble Case or Improvement Case, from chain tension checks to safe lockout points.Completed one point lessons for twelve months, each tied to equipment with its theme and OPL type, Basichttps://www.maintwiz.com/wp-content/uploads/tpm/ps-opl-pdf-export-one-sheet.webpOPL-2026-0102 exported as a one-page PDF for the conveyor drive: theme, lesson, three numbered step pictures and the initiator, verifier and approver blocks, ready to post at the machine.OPL-2026-0102 exported as a one-page PDF for the conveyor drive: theme, lesson, three numbered step pictureshttps://www.maintwiz.com/wp-content/uploads/tpm/ps-opl-record-form-classification-pillar-steps-v2.webpThe OPL form for Conveyor Belt C-12: classification, SHE pillar, the theme and the lesson text, steps with images, and initiator, verifier and approver.The OPL form for Conveyor Belt C-12: classification, SHE pillar, the theme and the lesson text, steps with https://www.maintwiz.com/product/quality-defect-management-software/https://www.maintwiz.com/wp-content/uploads/tpm/ps-qd-matrix-report-defect-by-area.webpThe QD matrix report counts 55 rejection records by phenomenon and plant area: surface blemish on Line 1 and contamination at Mixing stand out as the repeat defects for Hinshitsu Hozen to attack first.The QD matrix report counts 55 rejection records by phenomenon and plant area: surface blemish on Line 1 andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-qm-dashboard-rejection-rca-and-complaints-slate.webpThe quality dashboard: rejection RCA compliance at 85.45% (47 of 55 records with an RCA), rejections by line, customer complaints by status and the rejection phenomena behind them, surface blemish first.The quality dashboard: rejection RCA compliance at 85.45% (47 of 55 records with an RCA), rejections by line,https://www.maintwiz.com/wp-content/uploads/tpm/ps-rejection-rca-list-phenomenon-defect-class.webpEach rejection is listed with equipment, shift, phenomenon and defect class, and the reason found is classed by 4M, machine, method, material or manpower, so equipment-caused defects go to maintenance.Each rejection is listed with equipment, shift, phenomenon and defect class, and the reason found is classed https://www.maintwiz.com/product/near-miss-bbso-software/https://www.maintwiz.com/wp-content/uploads/tpm/ps-bbso-observation-form-behaviours-and-follow-up-v2.webpA BBSO observation on one screen: location, shift and category, the PPE seen (helmet worn, gloves missing), what was observed and corrected on the spot, the remark from the toolbox talk and who follows up.A BBSO observation on one screen: location, shift and category, the PPE seen (helmet worn, gloves missing),https://www.maintwiz.com/wp-content/uploads/tpm/ps-mobile-bbso-observation-phone.webpA supervisor records a BBSO observation on a phone at the filter station: location, category, the PPE seen, what was observed and a photo, saved to the SHE module before leaving the line.A supervisor records a BBSO observation on a phone at the filter station: location, category, the PPE seen,https://www.maintwiz.com/wp-content/uploads/tpm/ps-near-miss-form-location-severity-assignees.webpA near miss on Conveyor Belt C-12 is reported with its exact location, the outfeed walkway guard side, severity potential Major, probable occurrence Occasional and the people assigned, in one form.A near miss on Conveyor Belt C-12 is reported with its exact location, the outfeed walkway guard side,https://www.maintwiz.com/wp-content/uploads/tpm/ps-near-miss-register-list-severity-and-occurrence.webpThe near miss register by status, Open, Completed, Auditee Work Completed, Closed and Cancelled, with location, equipment, severity potential and probable occurrence, so a major, frequent near miss on a conveyor rises to the top.The near miss register by status, Open, Completed, Auditee Work Completed, Closed and Cancelled, withhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-she-dashboard-incident-reporting-compliance-v2.webpThe SHE dashboard for twelve months: 22 safety permits, 3 incidents and 47 near-miss observations, incident-reporting compliance at 91.70% within the site rule, and records split into near miss, minor and major.The SHE dashboard for twelve months: 22 safety permits, 3 incidents and 47 near-miss observations, https://www.maintwiz.com/product/early-equipment-management-software/https://www.maintwiz.com/wp-content/uploads/tpm/ps-cf-dashboard-mp-sheets-by-facility.webpMP sheet analytics in the common functions dashboard: 142 MP sheets in twelve months, 61 from Plant 1 and 47 from Plant 2, the lessons ready for the next equipment specification.MP sheet analytics in the common functions dashboard: 142 MP sheets in twelve months, 61 from Plant 1 and 47https://www.maintwiz.com/wp-content/uploads/tpm/ps-mp-sheet-completed-list.webpCompleted MP sheets for twelve months, each tied to a facility line, an equipment code and its creator, from the filler and gearbox drive to the conveyor guard sheet MP-2026-0014.Completed MP sheets for twelve months, each tied to a facility line, an equipment code and its creator, fromhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mp-sheet-form-header-theme-problem-v2.webpMP sheet MP-2026-0014 for Conveyor Belt C-12: improvement theme to eliminate an unsafe condition, the problem of operators reaching over the moving belt to clear jams, and the cause, an unguarded drive.MP sheet MP-2026-0014 for Conveyor Belt C-12: improvement theme to eliminate an unsafe condition, the problemhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mp-sheet-necessity-classification-design-failure.webpThe same MP sheet classified: horizontal deployment ticked, feedback a must, a change of mechanism and construction, cause a design failure, target maintainability improvement, standardised into the engineering standard document for the next specification.The same MP sheet classified: horizontal deployment ticked, feedback a must, a change of mechanism andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mp-sheet-pdf-export-a4.webpMP sheet MP-2026-0014 exported as a PDF for the design review of the next conveyor: problem, cause, countermeasure, classification and the standard it updates on one printable page.MP sheet MP-2026-0014 exported as a PDF for the design review of the next conveyor: problem, cause, https://www.maintwiz.com/product/ai-cmms-kaizen/https://www.maintwiz.com/wp-content/uploads/tpm/ps-cf-dashboard-kaizen-facility-department.webpKaizen analytics in the common functions dashboard: 318 Kaizen records over twelve months, by facility, with Plant 1 at 142, and by department, with production teams raising 131 and maintenance 96.Kaizen analytics in the common functions dashboard: 318 Kaizen records over twelve months, by facility, withhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-cf-dashboard-poka-yoke-by-facility.webpPoka-yoke records by facility in the common functions dashboard: 96 error-proofing records over twelve months, with Plant 1 at 41, Plant 2 at 33, Utilities at 14 and the Warehouse at 8.Poka-yoke records by facility in the common functions dashboard: 96 error-proofing records over twelvehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-kaizen-idea-sheet-form-before-image-drawn.webpOne idea sheet holds the idea, the horizontal plan to Line 2 and Line 3 fillers, the before scenario, the benchmark of 6 stops a month, the target of 2 and the before picture.One idea sheet holds the idea, the horizontal plan to Line 2 and Line 3 fillers, the before scenario, thehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-kaizen-idea-sheet-list-open-completed-cancelled.webpThe Kaizen idea sheet list holds every idea by status, Open, Completed or Cancelled, with area, title, benchmark and target side by side, such as filler guard: 6 stops a month to 2.The Kaizen idea sheet list holds every idea by status, Open, Completed or Cancelled, with area, title, https://www.maintwiz.com/product/ai-maintenance-competency-management/https://www.maintwiz.com/wp-content/uploads/tpm/ps-et-dashboard-training-sessions-and-attendance-slate.webpThe E&T dashboard counts 117 training sessions, 79 completed, 247 training hours and 434 people trained, with enrolment and attendance by role and trained operators, technicians and supervisors by facility.The E&T dashboard counts 117 training sessions, 79 completed, 247 training hours and 434 people trained, withhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-et-training-plan-record-fields-sessions-and-effectiveness-v2.webpOne training plan record, 5S audit method for Plant 2 supervisors, holds the trainer, skill code, capacity and venue, the session with 12 enrolled and 11 attended, and the effectiveness check due a month later.One training plan record, 5S audit method for Plant 2 supervisors, holds the trainer, skill code, capacityhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-training-sessions-list-enrollment-tabs.webpTraining sessions move from Open for Enrollment to Closed, Completed or Cancelled; each carries facility, dates, trainer and skill, from Jishu Hozen step 2 to lockout basics, OPL writing and Kaizen sheet writing.Training sessions move from Open for Enrollment to Closed, Completed or Cancelled; each carries facility, https://www.maintwiz.com/tpm/tpm-software-buyers-guide/https://www.maintwiz.com/wp-content/uploads/tpm/ps-abnormality-register-list-status-tabs.webpCriterion 2 in MaintWiz: the abnormality register lists each efuda tag with its equipment, owner, tag colour and target date, with tabs for open, closed, completed, cancelled and non-conformance records (MaintWiz).Criterion 2 in MaintWiz: the abnormality register lists each efuda tag with its equipment, owner, tag colourhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-plant-rollup-loss-and-trend.webpCriterion 4 in MaintWiz: OEE rolls up from six equipment on three lines to the plant by planned time, with the loss split by factor and a daily OEE calendar (MaintWiz).Criterion 4 in MaintWiz: OEE rolls up from six equipment on three lines to the plant by planned time, with https://www.maintwiz.com/tpm/tpm-software-vs-cmms-vs-mes/https://www.maintwiz.com/wp-content/uploads/tpm/cmms-mes-eam-record-ownership-venn.webpAll three systems share one equipment list; the AI CMMS built for TPM records downtime, tags and OEE losses, the MES counts output and the EAM carries finance, so each record has one home.All three systems share one equipment list; the AI CMMS built for TPM records downtime, tags and OEE losses,https://www.maintwiz.com/wp-content/uploads/tpm/cmms-mes-sap-record-flow-web-services.webpA stop event from the MES becomes a loss code and work order in MaintWiz, and web services pass the work order to SAP PM and the spare part request to SAP MM.A stop event from the MES becomes a loss code and work order in MaintWiz, and web services pass the workhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-loss-master-type-subtype-category.webpThe OEE module inside MaintWiz holds the loss master: each loss type and subtype maps to availability, performance or quality, so stop events from an MES land on the right pillar (MaintWiz).The OEE module inside MaintWiz holds the loss master: each loss type and subtype maps to availability, https://www.maintwiz.com/tpm/mtbf-mttr-calculator/https://www.maintwiz.com/wp-content/uploads/tpm/failure-patterns-early-life-random-wear-out.webpThree failure patterns with the same MTBF need different work: early-life failures need better installation and start-up, random failures need condition checks, and wear-out failures need replacement at a set age.Three failure patterns with the same MTBF need different work: early-life failures need better installationhttps://www.maintwiz.com/wp-content/uploads/tpm/mtbf-mttr-timeline-quarter-2208h.webpOne equipment over the quarter 1 Jul to 30 Sep 2026: six failures and 17.5 hours of repair leave 2,190.5 operating hours, so MTBF is 365.1 hours and MTTR 2.9 hours.One equipment over the quarter 1 Jul to 30 Sep 2026: six failures and 17.5 hours of repair leave 2,190.5https://www.maintwiz.com/wp-content/uploads/tpm/ps-kpi-breakdown-occurrence-and-hours-by-month-and-day.webpBreakdown count and breakdown hours by month and by day come straight from MaintWiz work orders, which are the two inputs to MTBF and MTTR, so the calculator's sum runs every month without retyping.Breakdown count and breakdown hours by month and by day come straight from MaintWiz work orders, which are https://www.maintwiz.com/tpm/downtime-reason-codes/https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-downtime-report-summary.webpOne month of coded stops in the MaintWiz downtime report: 183.3 lost hours from 187 events, split into unplanned 19.3 h, planned 15.7 h and performance loss 148.3 h, with reduced speed and minor stoppage the largest categories.One month of coded stops in the MaintWiz downtime report: 183.3 lost hours from 187 events, split intohttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-loss-master-type-subtype-category-v2.webpThe 38-code library loaded into the MaintWiz loss master: each code is set up once per equipment with its OEE loss type, six-loss sub type and planned or unplanned category, so every stop rolls up automatically.The 38-code library loaded into the MaintWiz loss master: each code is set up once per equipment with its OEEhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-production-log-entry-form-stop-reason-code.webpA stop entered in MaintWiz with its equipment, start and end time, product, reason code and supervisor confirmation; breakdown stops and their repair work orders sit on the same equipment, and the work orders' breakdown count and hours feed MTBF and MTTR.A stop entered in MaintWiz with its equipment, start and end time, product, reason code and supervisorhttps://www.maintwiz.com/wp-content/uploads/tpm/tpl-preview-downtime-code-library-sheet-v2.webpThe free downtime reason-code workbook as it opens in Excel: each of the 38 codes with its six big losses group, OEE factor, 16 major losses group and planned or unplanned flag, ready to rename for your plant.The free downtime reason-code workbook as it opens in Excel: each of the 38 codes with its six big losses https://www.maintwiz.com/tpm/cil-standards/https://www.maintwiz.com/wp-content/uploads/tpm/cil-standard-point-map-pump-set-numbered.webpA CIL standard starts from a numbered drawing: each of the eight points on this pump set has one task, clean, inspect, lubricate or tighten, and one row in the standard that says what good looks like.A CIL standard starts from a numbered drawing: each of the eight points on this pump set has one task, clean,https://www.maintwiz.com/wp-content/uploads/tpm/ps-mobile-service-order-clita-phones.webpThe same service order on a phone: the operator sees the equipment and status, ticks the CLITA activities, works down the checklist with an observation per task, then saves or creates a work order.The same service order on a phone: the operator sees the equipment and status, ticks the CLITA activities,https://www.maintwiz.com/wp-content/uploads/tpm/ps-service-order-clita-activities.webpA CIL standard runs as a service order in MaintWiz: the operator ticks the clean, lubricate, inspect, re-tighten and adjust activities done, adds work instructions and notes, and closes the checklist task by task.A CIL standard runs as a service order in MaintWiz: the operator ticks the clean, lubricate, inspect,https://www.maintwiz.com/wp-content/uploads/tpm/tpl-preview-cil-standards-sheet-pump-set.webpILLUSTRATION. The CIL standards workbook filled for the pump set: one row per numbered point, with what good looks like, the method and tool, the lubricant, the minutes and the frequency.ILLUSTRATION https://www.maintwiz.com/tpm/autonomous-maintenance-step-1/https://www.maintwiz.com/wp-content/uploads/tpm/initial-cleaning-fix-now-or-tag-motor-gearbox-numbered.webpFive finds on one motor-gearbox set during initial cleaning: two are fixed on the spot, one gets a white tag for operators and two get red tags for maintenance, following the fix-now-or-tag rule.Five finds on one motor-gearbox set during initial cleaning: two are fixed on the spot, one gets a white taghttps://www.maintwiz.com/wp-content/uploads/tpm/ps-jishu-hozen-abnormality-register-form-completed.webpEach step 1 tag becomes a register entry in MaintWiz: ABN number, equipment, nature of issue, fuguai tag colour, the person assigned and the time taken, here for an oil seep at a gearbox output seal.Each step 1 tag becomes a register entry in MaintWiz: ABN number, equipment, nature of issue, fuguai tag https://www.maintwiz.com/tpm/autonomous-maintenance-step-2/https://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-contamination-and-hard-to-access.webpThe MaintWiz Jishu Hozen dashboard charts step 2 findings from the abnormality register: source of contamination and hard-to-access records, each split into assigned, closed and completed, so the team sees which sources are still open.The MaintWiz Jishu Hozen dashboard charts step 2 findings from the abnormality register: source ofhttps://www.maintwiz.com/wp-content/uploads/tpm/step-2-contamination-sources-hard-to-access-numbered-drawing.webpStep 2 on the conveyor drive: the seal leak is removed at source, spill is contained and collected, and a window, remote grease line and hinged cover cut the time to clean and inspect.Step 2 on the conveyor drive: the seal leak is removed at source, spill is contained and collected, and a https://www.maintwiz.com/tpm/kaizen-sheet-format/https://www.maintwiz.com/wp-content/uploads/tpm/kaizen-a3-report-template-filled-example-v2.webpThe Kaizen A3 report template, filled with a labeller minor-stop example: eight sections read left to right, from theme and baseline to results and the updated standard (ILLUSTRATION).The Kaizen A3 report template, filled with a labeller minor-stop example: eight sections read left to right,https://www.maintwiz.com/wp-content/uploads/tpm/poka-yoke-sheet-format-detection-and-function.webpA poka-yoke sheet records the error it prevents, how the device detects it (contact, fixed-value or motion-step), whether it stops the process or warns, and how often the device itself is checked.A poka-yoke sheet records the error it prevents, how the device detects it (contact, fixed-value orhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-kaizen-idea-sheet-form-before-image-and-target.webpA Kaizen idea sheet as a form: idea in 95 characters, horizontal plan, before scenario, benchmark and target, dates and the before image or video, the same fields as the paper sheet (MaintWiz).A Kaizen idea sheet as a form: idea in 95 characters, horizontal plan, before scenario, benchmark and target, https://www.maintwiz.com/tpm/tpm-organisation-and-roles/https://www.maintwiz.com/wp-content/uploads/tpm/ps-action-items-and-meetings-tracker.webpEvery area, pillar and steering meeting leaves action items with an owner and a due date in MaintWiz, so the TPM lead sees overdue actions by pillar before each weekly review instead of chasing minutes.Every area, pillar and steering meeting leaves action items with an owner and a due date in MaintWiz, so thehttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-promotion-organisation-overlapping-small-groups.webpA TPM promotion organisation links three levels through overlapping small groups: the plant head's steering committee, eight pillar committees and the area Jishu Hozen circles, with each leader sitting in the group above.A TPM promotion organisation links three levels through overlapping small groups: the plant head's steering https://www.maintwiz.com/tpm/pm-analysis/https://www.maintwiz.com/wp-content/uploads/tpm/pm-analysis-conditions-to-4m-factor-tree.webpP-M analysis fans out from one phenomenon to every condition that could cause it and every machine, man, material and method factor behind each condition, so no contributing cause is left unmeasured.P-M analysis fans out from one phenomenon to every condition that could cause it and every machine, man,https://www.maintwiz.com/wp-content/uploads/tpm/pm-analysis-physical-explanation-label-applicator.webpStep 3 of P-M analysis explains the wrinkle physically: tension that differs across the label web at the peel plate lets one edge lead, and the wipe brush folds the slack edge onto the pack.Step 3 of P-M analysis explains the wrinkle physically: tension that differs across the label web at the peelhttps://www.maintwiz.com/wp-content/uploads/tpm/pm-analysis-worksheet-filled-label-wrinkle.webpA filled P-M analysis worksheet for wrinkled labels: one phenomenon, its physical principle, three conditions, the 4M factors behind each, standards and measured values, and the out-of-standard factors corrected (ILLUSTRATION).A filled P-M analysis worksheet for wrinkled labels: one phenomenon, its physical principle, threehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-rejection-rca-list-phenomenon-defect-class.webpEach chronic defect gets its own root-cause record with the phenomenon, the defect class and the equipment, so a P-M analysis team works from the logged occurrences and closes the record when the loss falls (MaintWiz).Each chronic defect gets its own root-cause record with the phenomenon, the defect class and the equipment, https://www.maintwiz.com/tpm/autonomous-maintenance-steps-4-5/https://www.maintwiz.com/wp-content/uploads/tpm/general-inspection-gearbox-check-points-numbered.webpSotenken (general inspection) on a gearbox: operators learn what each of the nine numbered points does and how it fails, then inspect against the marks on the equipment rather than from memory.Sotenken (general inspection) on a gearbox: operators learn what each of the nine numbered points does andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-opl-record-form-classification-pillar-steps-v2.webpInspection skills taught in step 4 are kept as one point lessons in MaintWiz: classification, pillar, theme and illustrated steps, with initiator, verifier and approver, and a PDF to post at the equipment.Inspection skills taught in step 4 are kept as one point lessons in MaintWiz: classification, pillar, theme https://www.maintwiz.com/tpm/autonomous-maintenance-steps-6-7/https://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-facility-pareto-and-monthly-change.webpIn step 7 the team reads its own data in MaintWiz: tags by facility as a Pareto with the change from last month, so it sets its own targets and picks the next improvement.In step 7 the team reads its own data in MaintWiz: tags by facility as a Pareto with the change from lasthttps://www.maintwiz.com/wp-content/uploads/tpm/visual-controls-on-equipment-numbered.webpVisual controls that make a standard checkable at a glance: gauge green band, match marks, level band, flow and rotation arrows, lubricant colour tags, numbered point discs and a reference photo.Visual controls that make a standard checkable at a glance: gauge green band, match marks, level band, flow https://www.maintwiz.com/tpm/autonomous-maintenance-vs-preventive-maintenance/https://www.maintwiz.com/wp-content/uploads/tpm/am-vs-pm-task-split-pump-set-numbered.webpOne pump set, three kinds of task: operators clean, look and listen at points 1 to 5, maintenance keeps points 6 to 9, and point 10 moves to operators once step 4 training is passed.One pump set, three kinds of task: operators clean, look and listen at points 1 to 5, maintenance keepshttps://www.maintwiz.com/wp-content/uploads/tpm/ps-mobile-service-order-clita-phones.webpThe operator's service order on a phone: equipment and status, the CLITA activities ticked, a checklist with an observation per task, and Create WO when maintenance work is needed.The operator's service order on a phone: equipment and status, the CLITA activities ticked, a checklist withhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-pm-dashboard-compliance-and-work-order-types.webpMaintWiz shows the preventive side next to Jishu Hozen: PM checklist compliance, closed against open, and work orders by type, so both halves of the split are reviewed in one CMMS.MaintWiz shows the preventive side next to Jishu Hozen: PM checklist compliance, closed against open, andhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-service-order-clita-activities.webpOperators record their CLITA routines on a service order, with the activities done, instructions and a checklist, while maintenance runs preventive work from PM schedules and work orders on the same equipment.Operators record their CLITA routines on a service order, with the activities done, instructions and a https://www.maintwiz.com/tpm/tpm-india-cii-tpm-club/https://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-contamination-and-hard-to-access.webpMaintWiz counts Jishu Hozen source-of-contamination and hard-to-access records as assigned, closed and completed, the step 2 progress that comes before CII's step 3 threshold of 25 to 30% of machines for the Strong Commitment certificate.MaintWiz counts Jishu Hozen source-of-contamination and hard-to-access records as assigned, closed and https://www.maintwiz.com/tpm/what-is-tpm-software/https://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-dashboard-pm-jh-she-overview.webpThe TPM dashboard overview in MaintWiz reads three pillars on one screen: planned maintenance with PM compliance of 93.40 per cent, Jishu Hozen red and white tag status, and safety permits, incidents and near misses (MaintWiz).The TPM dashboard overview in MaintWiz reads three pillars on one screen: planned maintenance with PMhttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-software-seven-step-jishu-hozen-record-trail.webpThe seven Jishu Hozen steps from initial cleaning to autonomous management, with the record each step leaves in TPM software: efuda tags, sources of contamination, CIL standards, inspection checks and step audits.The seven Jishu Hozen steps from initial cleaning to autonomous management, with the record each step leaves https://www.maintwiz.com/tpm/tpm-software-pricing/https://www.maintwiz.com/wp-content/uploads/tpm/tpm-rollout-6-to-8-weeks-plan.webpThe whole TPM goes live in 6 to 8 weeks: equipment and checklists load from Excel in week one, Jishu Hozen and tags follow, and the dashboard for each pillar runs by week eight with guided project management.The whole TPM goes live in 6 to 8 weeks: equipment and checklists load from Excel in week one, Jishu Hozen https://www.maintwiz.com/tpm/tpm-software-india/https://www.maintwiz.com/wp-content/uploads/tpm/ps-mobile-capture-tag-5s-audit-work-order-phones.webpOperators raise abnormality tags, 5S audits and quick work orders from a phone in MaintWiz. Masters load from Excel templates and every record exports to XLS and PDF.Operators raise abnormality tags, 5S audits and quick work orders from a phone in MaintWizhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-kpi-overview-by-pillar.webpThe MaintWiz KPI overview by pillar: one block each for autonomous maintenance, planned maintenance, focused improvement, quality, safety and training, the evidence CII assessors ask for at each rung.The MaintWiz KPI overview by pillar: one block each for autonomous maintenance, planned maintenance, focused https://www.maintwiz.com/tpm/tpm-software-sap-integration/https://www.maintwiz.com/wp-content/uploads/tpm/ps-equipment-register-list-criticality-and-class.webpThe MaintWiz equipment register, the list that SAP PM feeds: each machine keeps its code, class and criticality, so tags, CIL checks and work orders post against the same equipment (MaintWiz).The MaintWiz equipment register, the list that SAP PM feeds: each machine keeps its code, class andhttps://www.maintwiz.com/wp-content/uploads/tpm/sap-pm-mm-maintwiz-ai-cmms-web-services-diagram.webpWeb services link SAP PM and SAP MM to MaintWiz: equipment and materials come from SAP, work orders raised from TPM tags go back, and the objects, direction and frequency are agreed before go-live.Web services link SAP PM and SAP MM to MaintWiz: equipment and materials come from SAP, work orders raised https://www.maintwiz.com/tpm/tpm-software-gcc-usa-uk-europe/https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-line-rollup-jan-2025.webpA line-level OEE roll-up in MaintWiz: availability, performance and quality losses for Line A beside a day-wise OEE heat map, the view multi-site buyers ask to see in a demo.A line-level OEE roll-up in MaintWiz: availability, performance and quality losses for Line A beside a https://www.maintwiz.com/tpm/maintwiz-tpm-software/https://www.maintwiz.com/wp-content/uploads/tpm/ps-equipment-register-list-criticality-and-class.webpYour equipment list loads from an Excel upload and holds each machine with its code, class and criticality, so tags, audits, lessons and work orders attach to the same machine from the first week.Your equipment list loads from an Excel upload and holds each machine with its code, class and criticality,https://www.maintwiz.com/wp-content/uploads/tpm/ps-manager-dashboard-approvals-and-breakdowns.webpThe manager's view: 12 work orders and reports awaiting approval, breakdown hours and count for twelve months, PM compliance at 93.4% and the six-month breakdown trend falling from 52 to 39 occurrences.The manager's view: 12 work orders and reports awaiting approval, breakdown hours and count for twelvehttps://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-programme-dashboard-hero.webpThe MaintWiz TPM programme dashboard: OEE for a line with availability, performance and quality, and one tile per pillar with its records, filtered by facility and period.The MaintWiz TPM programme dashboard: OEE for a line with availability, performance and quality, and one tile https://www.maintwiz.com/tpm/tpm-by-industry/https://www.maintwiz.com/wp-content/uploads/tpm/cement-kiln-drive-jishu-hozen-inspection-points.webpA cement kiln drive with five numbered Jishu Hozen points: motor and gearbox lubrication, girth-gear spray, support-roller bearing temperature, coupling alignment and dust seals, the daily checks that stop heat and dust breakdowns.A cement kiln drive with five numbered Jishu Hozen points: motor and gearbox lubrication, girth-gear spray,https://www.maintwiz.com/wp-content/uploads/tpm/ps-qm-dashboard-rejection-rca-and-complaints.webpIn batch and process plants the quality maintenance dashboard leads: rejections traced to equipment conditions through RCA, and customer complaints logged against the line, so Hinshitsu Hozen works from the plant's own defect record.In batch and process plants the quality maintenance dashboard leads: rejections traced to equipment https://www.maintwiz.com/tpm/tpm-award-winners-by-country/https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-dashboard-ar-pr-qr-trends-and-lost-hours-pareto.webpMaintWiz trends availability, performance and quality rate by month and ranks lost hours in a Pareto, the loss record award-winning plants use to choose each Kobetsu Kaizen theme.MaintWiz trends availability, performance and quality rate by month and ranks lost hours in a Pareto, thehttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-award-entries-outside-japan-by-year.webpJIPM recorded 1,569 TPM award entries outside Japan from 2006 to 2025, between 49 and 98 a year. Entries fell to 49 in 2020 and recovered to 80 in 2023, giving 335 in 2021-25.JIPM recorded 1,569 TPM award entries outside Japan from 2006 to 2025, between 49 and 98 a year https://www.maintwiz.com/tpm/tpm-software-china/https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-plant-rollup-jan-2025.webpMaintWiz rolls OEE up from equipment to line and plant, weighted by planned time. Plant A's January view splits availability, performance and quality loss beside a day-by-day OEE heat map.MaintWiz rolls OEE up from equipment to line and plant, weighted by planned time https://www.maintwiz.com/tpm/tpm-software-thailand-asean/https://www.maintwiz.com/wp-content/uploads/tpm/ps-tpm-dashboard-pm-jh-she-overview.webpThe MaintWiz TPM overview puts PM compliance, Jishu Hozen red and white tag closure and safety records on one screen, which is how sustaining plants keep routines visible between JIPM assessments.The MaintWiz TPM overview puts PM compliance, Jishu Hozen red and white tag closure and safety records on one https://www.maintwiz.com/tpm/tpm-software-latin-america/https://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-dashboard-loss-stratification-and-oee-trend.webpMaintWiz stratifies OEE loss into availability, performance and quality for one line and trends OEE by month, the view food and beverage plants use to pick the next Kobetsu Kaizen theme.MaintWiz stratifies OEE loss into availability, performance and quality for one line and trends OEE by month, https://www.maintwiz.com/tpm/tpm-software-turkey-europe/https://www.maintwiz.com/wp-content/uploads/tpm/ps-jh-dashboard-day-wise-tag-closure.webpDay-wise Jishu Hozen tag closure in MaintWiz. Plants restarting a lapsed programme watch tags raised against tags closed each day until the backlog returns to the standard set at the last step audit.Day-wise Jishu Hozen tag closure in MaintWiz https://www.maintwiz.com/tpm/tpm-software-comparison/https://www.maintwiz.com/wp-content/uploads/tpm/jipm-eight-pillars-house-5s-base.webpThe eight JIPM pillars this comparison measures each tool against, from Jishu Hozen and Kobetsu Kaizen to early equipment management and Office TPM, standing on Seiri, Seiton, Seiso, Seiketsu and Shitsuke.The eight JIPM pillars this comparison measures each tool against, from Jishu Hozen and Kobetsu Kaizen tohttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-dashboard-collage-web-tablet-mobile.webpOne AI CMMS built for TPM, one dashboard per pillar: the programme dashboard on the web, the Jishu Hozen tag dashboard on a tablet and tag capture on a phone (MaintWiz).One AI CMMS built for TPM, one dashboard per pillar: the programme dashboard on the web, the Jishu Hozen tag https://www.maintwiz.com/tpm/maintwiz-vs-maintainx-for-tpm/https://www.maintwiz.com/wp-content/uploads/tpm/ps-abnormality-register-list-status-tabs.webpThe MaintWiz abnormality register lists each efuda tag with its equipment, owner, tag colour and target date, with tabs for open, closed, completed, cancelled and non-conformance records (MaintWiz).The MaintWiz abnormality register lists each efuda tag with its equipment, owner, tag colour and target date,https://www.maintwiz.com/wp-content/uploads/tpm/ps-kaizen-idea-sheet-form-before-image-and-target.webpA Kobetsu Kaizen idea sheet in MaintWiz records the equipment, the idea, the before scenario, the benchmark and the target, with a before image, an area MaintainX's public pages state only in part (MaintWiz).A Kobetsu Kaizen idea sheet in MaintWiz records the equipment, the idea, the before scenario, the benchmarkhttps://www.maintwiz.com/wp-content/uploads/tpm/tpm-dashboard-collage-web-tablet-mobile-v2.webpOne system across the eight pillars: the programme dashboard where every tile opens its pillar dashboard, the red tag records behind the Jishu Hozen tile, and the phone form that raises a tag.One system across the eight pillars: the programme dashboard where every tile opens its pillar dashboard, the https://www.maintwiz.com/tpm/maintwiz-vs-weever-for-tpm/https://www.maintwiz.com/wp-content/uploads/tpm/ps-cf-dashboard-kaizen-facility-department.webpKobetsu Kaizen on the same AI CMMS: MaintWiz counts Kaizen records by facility and department, a pillar Weever's public pages did not state when read on 2 November 2026 (MaintWiz).Kobetsu Kaizen on the same AI CMMS: MaintWiz counts Kaizen records by facility and department, a pillarhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-plant-rollup-loss-and-trend.webpThe OEE module in MaintWiz rolls six equipment on three lines up to the plant, with the loss split by factor and a daily OEE calendar, so planned maintenance, tags and losses sit on one AI CMMS built for TPM (MaintWiz).The OEE module in MaintWiz rolls six equipment on three lines up to the plant, with the loss split by factorhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-pm-dashboard-compliance-and-work-order-types.webpKeikaku Hozen in MaintWiz: PM compliance of 93.4 per cent, breakdown hours and work orders split by preventive, corrective, breakdown, inspection and predictive type, month by month (MaintWiz).Keikaku Hozen in MaintWiz: PM compliance of 93.4 per cent, breakdown hours and work orders split by https://www.maintwiz.com/tpm/maintwiz-vs-fabrico-teeptrak-oee/https://www.maintwiz.com/wp-content/uploads/tpm/oee-loss-to-tpm-pillar-routing.webpOEE counts the loss and each loss goes to the pillar routine that removes it: breakdowns to planned maintenance work orders, minor stops to efuda tags, chronic losses to Kobetsu Kaizen and defects to Hinshitsu Hozen.OEE counts the loss and each loss goes to the pillar routine that removes it: breakdowns to plannedhttps://www.maintwiz.com/wp-content/uploads/tpm/ps-oee-lost-hours-pareto-and-oee-by-month-v2.webpThe OEE module in MaintWiz ranks 183.3 lost hours by reason, led by speed losses on material and tooling, beside the monthly OEE trend for Line A, July 2025 to July 2026 (MaintWiz).The OEE module in MaintWiz ranks 183.3 lost hours by reason, led by speed losses on material and tooling,