TPM Templates and Tools: 140 Free Excel and PDF Files for Plant Teams

Day one

What does each TPM template give you on day one?

• A Dashboard first: results and charts open on the first sheet, with a worked example marked Sample data.
• Input cells are marked, calculated cells are locked, and a Setup sheet holds legends and thresholds.
• Print-ready pages on A4; wall charts print on one large sheet or two A4 pages.
• A Read me last: purpose, how to use it, related files, version and change log.
• A QR code on the print pages that opens WhatsApp or the demo booking.

The calculators on the OEE calculator and self-assessment pages run in the browser; the workbooks add history, roll-ups and print reports.

• 14Start and plan
• 16Autonomous maintenance, tags and 5S
• 17Losses, OEE and improvement
• 23Maintenance, quality, safety, training and design
• 70Measure, review and decide

All 140 TPM templates…

All 140 TPM templates by pillar, role and format

Choose a pillar, a role or a format, or type a word such as tag, OEE or audit. The library holds 90 Excel workbooks, 49 PDF files and one PowerPoint deck.

140 files

All TPM templates and tools by pillar, role and format

Preview	File	Pillar	Role	Format	Method	Get
	Small group activity register and meeting log (Jishu Hozen circles and Kaizen themes)Register every small group, log its meetings and track Jishu Hozen circles up the seven steps or Kaizen themes up	Jishu Hozen	Operator, JH leader, TPM coordinator	Excel	Jishu Hozen	Get it
	8 pillars of TPM (one-page PDF with Japanese terms)The eight pillars on one page with Japanese names, zero goal, lead KPI and where each sits in MaintWiz	TPM programme	TPM coordinator, Plant Head, Operator	PDF A4	Total Productive Maintenance	Get it
	Pilot asset selection matrixRank candidate assets on weighted criteria with safety and baseline-data gates	TPM programme	TPM coordinator, Plant Head	Excel	TPM implementation	Get it
	TPM 90-day plan (one-page wall sheet)A one-page A4 wall sheet of the 90-day plan with owner lines and the 6 to 8 week roll-out lane underneath	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM implementation	Get it
	TPM 90-day starter roadmapSeven dated phases for the first 90 days, with the 6 to 8 week MaintWiz roll-out running as a second lane	TPM programme	TPM coordinator, Plant Head	Excel	TPM implementation	Get it
	TPM Champion weekly routine, Gemba log and action trackerA daily-to-quarterly routine for the TPM Champion, with step audits and Yokoten	TPM programme	TPM coordinator, Plant Head	Excel	TPM roles and responsibilities	Get it
	TPM glossary: 40 Japanese and English terms (folds to pocket size)Forty Japanese and English TPM terms on one A4 sheet that folds to pocket size	TPM programme	TPM coordinator, Plant Head, Operator, JH leader	PDF A4	TPM glossary	Get it
	TPM master plan template: 12 steps and 3-year pillar GanttPlan the 12 TPM steps and a three-year Gantt by pillar and quarter	TPM programme	TPM coordinator, Plant Head	Excel	TPM implementation	Get it
	TPM pillar activity boardPost one plant board and one pillar board with PQCDSM targets, the OEE trend, Gemba walk notes	TPM programme	TPM coordinator, Plant Head	PDF A3	Total Productive Maintenance	Get it
	TPM pillar charter and annual planStart each of the eight pillars from a charter with its aim, zero goal, step model and three lead KPIs	TPM programme	TPM coordinator, Plant Head	Excel	TPM implementation	Get it
	TPM pillar priority selector: 16 major losses to pillar sequenceEnter your 16 major losses and see which TPM pillar to start first	TPM programme	TPM coordinator, Plant Head	Excel	TPM glossary	Get it
	TPM promotion organisation and RACI matrixNine roles across 40 TPM activities with a one-accountable check	TPM programme	TPM coordinator, Plant Head	Excel	TPM roles and responsibilities	Get it
	TPM readiness guide: score 12 dimensions, find the gap, plan the first 90 daysScore 12 dimensions, read the gap with a worked example, and follow the 90-day plan with the 6 to 8 week roll-out lane	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM self-assessment	Get it
	TPM readiness self-assessment and pillar audit workbookScore 27 questions across 12 dimensions, read a readiness index from 0 to 100 and your place on the 12 steps	TPM programme	TPM coordinator, Plant Head	Excel	TPM self-assessment	Get it
	5S audit print formScore 25 checks on paper for any zone, with ready versions for a production line, an office and a store	5S	Operator, JH leader, TPM coordinator	PDF A4	5S in TPM	Get it
	5S zone plan and rollout tracker (1S to 3S by zone, with zone map)Plan zones, owners and dates for the five S, colour a zone map by audit score	5S	Operator, JH leader, TPM coordinator	Excel	5S in TPM	Get it
	Shadow board template and 5S location labels (Excel, prints labels)List tools and locations, print the shadow board layout and label sheets	5S	Operator, JH leader, TPM coordinator	Excel	5S in TPM	Get it
	Autonomous maintenance checklist and CIL standards (Excel)Write each cleaning, inspection and lubrication standard once, print the daily operator checklist for any machine	Jishu Hozen	Operator, JH leader, TPM coordinator	Excel	Autonomous maintenance checklist	Get it
	Autonomous maintenance step coverage planner (plan v actual by quarter)See how many machines have passed each Jishu Hozen step against your quarterly plan	Jishu Hozen	Operator, JH leader, TPM coordinator	Excel	TPM in India	Get it
	CIL map and lubrication chart: 24 points, 6 lube coloursSketch the machine, number up to 24 points, and give each lubricant one code and colour so the right grease reaches	Jishu Hozen	Operator, JH leader, TPM coordinator	PDF A4	CIL standards	Get it
	CIL standard print formPost one page per machine with each point, standard, machine state and PPE	Jishu Hozen	Operator, JH leader, TPM coordinator	PDF A4	CIL standards	Get it
	Daily CIL check sheet (monthly and weekly)Print a daily operator checklist for one machine, monthly or weekly with A, B and C shift boxes	Jishu Hozen	Operator, JH leader, TPM coordinator	PDF A4	Autonomous maintenance checklist	Get it
	Jishu Hozen 7-step wall chart (with Japanese step names and three-tier audit)Post the seven Jishu Hozen steps at the machine with Self, Manager and Top audit boxes	Jishu Hozen	Operator, JH leader, TPM coordinator	PDF A3	Jishu Hozen	Get it
	Jishu Hozen step audit scorecard (shindan, step 0 to 7, three-tier sign-off)Audit every machine through the seven Jishu Hozen steps with self, manager and top audits	Jishu Hozen	Operator, JH leader, TPM coordinator	Excel	Autonomous maintenance step 1	Get it
	TPM abnormality tags (fuguai efuda): red, white and yellow tag cards, printablePrint two-part red, white and yellow tags with a tear-off stub, priority and step boxes, eight per A4	Jishu Hozen	Operator, JH leader, TPM coordinator	PDF A4	Red tag system	Get it
	TPM red, white and yellow tag register (fuguai efuda): closure, self-fix and ageingLog every abnormality tag, see closure rate and self-fix rate by colour, and find overdue tags before an audit does	Jishu Hozen	Operator, JH leader, TPM coordinator	Excel	Red tag system	Get it
	Visual controls for autonomous maintenance: printable gauge, flow, level and match-mark labelsPrint gauge range arcs, flow arrows, lubricant discs, valve tags and level strips at actual size	Jishu Hozen	Operator, JH leader, TPM coordinator	PDF A4	Autonomous maintenance steps 4 and 5	Get it
	One point lesson print formPrint-ready A4 one point lesson with before and after pictures, a trainee sign-off grid and three filled examples	Education and training	TPM coordinator, Operator, JH leader	PDF A4	One point lesson	Get it
	One point lesson template with worked example, trainee sign-off and logFill a one-page lesson with a worked chain tension example	Education and training	TPM coordinator, Operator, JH leader	Excel	One point lesson	Get it
	Daily 5S checklist (printable, 5 minutes per zone)Walk a zone in five minutes with a ten-check tick grid for Monday to Sunday, a score board and the three worst items	TPM programme	TPM coordinator, Plant Head, Operator	PDF A4	5S in TPM	Get it
	Cost of downtime calculator (six big losses, Excel)Turn hours lost to each of the six big losses into cost per line, with overtime recovery	Kobetsu Kaizen	TPM coordinator, PM engineer	Excel	Six big losses	Get it
	Kaizen A3 report template (Excel) with a worked exampleRun a Kobetsu Kaizen project as an A3 report, with the Line 2 labeller project filled in from loss ranking to Yokoten	Kobetsu Kaizen	TPM coordinator, PM engineer	Excel	Kobetsu Kaizen	Get it
	Kaizen idea sheet and A3 report formPrint the floor idea sheet and the A3 report form, plus a filled A3 report showing how a finished project reads	Kobetsu Kaizen	TPM coordinator, PM engineer, Operator	PDF A3	Kaizen sheet format	Get it
	Kaizen idea sheet and poka-yoke trackerCollect floor ideas by PQCDSM and E category, answer every one	Kobetsu Kaizen	TPM coordinator, PM engineer	Excel	Kaizen sheet format	Get it
	Kaizen savings and ROI calculator (project and portfolio)Test one Kaizen project for payback and ROI, then list up to 25 projects by loss to see which ones pay for the TPM	Kobetsu Kaizen	TPM coordinator, PM engineer	Excel	Kobetsu Kaizen	Get it
	Kobetsu Kaizen pillar audit (focused improvement step audit)Score 24 criteria across the seven Kobetsu Kaizen steps, see which step a team is stuck on, and track the actions	Kobetsu Kaizen	TPM coordinator, PM engineer	Excel	Kobetsu Kaizen	Get it
	Loss tree and Pareto-to-project mapBuild the loss tree from calendar time to valuable time, rank all 16 losses by cost	Kobetsu Kaizen	TPM coordinator, PM engineer	Excel	Kobetsu Kaizen	Get it
	P-M analysis worksheet (JIPM 8 steps, worked example)Work a chronic loss through the eight JIPM P-M analysis steps	Kobetsu Kaizen	TPM coordinator, PM engineer	Excel	P-M analysis	Get it
	Andon board and call log template (Excel)Run an andon line-stop call light with escalation at 10 and 20 minutes, response and fix times	OEE, losses and KPIs	PM engineer, TPM coordinator, Operator	Excel	Downtime reason codes	Get it
	Downtime reason-code library and stop logStart from 38 coded stop reasons with definitions, set a minor stop threshold	OEE, losses and KPIs	PM engineer, TPM coordinator, Operator	Excel	Downtime reason codes	Get it
	OEE calculator (Excel): shift OEE, six big losses and daily logType one shift and see OEE, the three factors and where every planned minute went	OEE, losses and KPIs	PM engineer, TPM coordinator	Excel	OEE calculator	Get it
	OEE formula cheat sheetKeep the OEE formulas, a worked 480-minute shift, the six big losses and the 16 major losses on one printable page	OEE, losses and KPIs	PM engineer, TPM coordinator	PDF A4	What is OEE	Get it
	OEE improvement value calculator: what one point is worthSee what one point of availability, performance or quality is worth in hours and good parts	OEE, losses and KPIs	PM engineer, TPM coordinator	Excel	Improve OEE	Get it
	OEE measurement guide (PDF): definitions, data capture and roll-upAgree one OEE definition, choose a data capture route and roll results up from equipment to plant	OEE, losses and KPIs	PM engineer, TPM coordinator	PDF A4	OEE calculator	Get it
	OEE roll-up calculator: equipment to line to plant (time-weighted)Roll equipment OEE up to line and plant by planned time	OEE, losses and KPIs	PM engineer, TPM coordinator, Plant Head	Excel	OEE calculator	Get it
	OEE shift data collection sheetPrint one sheet per shift and equipment: hourly counts, a coded stop log, efuda tag column and a product change line	OEE, losses and KPIs	PM engineer, TPM coordinator, Operator	PDF A4	OEE calculator	Get it
	Six big losses and 16 major losses worksheetLog loss events, rank the eight equipment losses in minutes	OEE, losses and KPIs	PM engineer, TPM coordinator	Excel	Six big losses	Get it
	Breakdown report and failure analysis formRecord a breakdown with failure-to-call time, a phenomenon sketch	Keikaku Hozen	PM engineer	PDF A4	Planned maintenance	Get it
	Equipment criticality analysis template (ABC ranking)Score equipment on safety, environment, production, standby and detectability, rank it A, B or C	Keikaku Hozen	PM engineer	Excel	Planned maintenance	Get it
	Keikaku Hozen (planned maintenance) 7-step audit: Step 0 to Step 6Score 28 criteria across Keikaku Hozen Step 0 to Step 6, see the weakest step and the zero-breakdown phase	Keikaku Hozen	PM engineer	Excel	Planned maintenance	Get it
	Maintenance job plan and SOP template (PDF)Print a job plan with isolation, PPE, steps, limits and acceptance	Keikaku Hozen	PM engineer	PDF A4	Planned maintenance	Get it
	MTBF and MTTR calculator (Excel) with availability and repeat failuresLog failures and read MTBF, MTTR, inherent and operational availability by asset	Keikaku Hozen	PM engineer, Plant Head	Excel	MTBF and MTTR calculator	Get it
	Preventive maintenance schedule template (Excel): 52-week plan and compliancePlan preventive maintenance on a 52-week calendar with calendar, running-hours and condition triggers	Keikaku Hozen	PM engineer	Excel	Planned maintenance	Get it
	QM matrix (Hinshitsu Hozen condition table) with check logSet standard values, limits and check frequency for every 4M condition behind a quality characteristic	Hinshitsu Hozen	PM engineer, TPM coordinator	Excel	Quality maintenance	Get it
	Quality maintenance pillar audit: find your Hinshitsu Hozen step (1 to 10)Score your Hinshitsu Hozen step from 1 to 10, with evidence for each of 24 criteria	Hinshitsu Hozen	PM engineer, TPM coordinator	Excel	Quality maintenance	Get it
	Early equipment management pillar auditAudit the Early Equipment Management pillar with scored criteria, a radar against your pass line and an action list	Early equipment management	PM engineer, TPM coordinator	Excel	Early equipment management	Get it
	EEM design review scorecard (maintainability checklist) with five phase gatesScore a new machine design on 24 criteria, back findings with MP sheets, and take a Go or Hold decision for each phase	Early equipment management	PM engineer, TPM coordinator	Excel	Early equipment management	Get it
	Vertical start-up tracker: initial-phase control from start-up to stable operationTrack start-up problems and losses week by week, compare days to stable with your target	Early equipment management	PM engineer, TPM coordinator	Excel	Early equipment management	Get it
	Education and training pillar auditScore the Kyoiku Kunren (education and training) pillar on 24 evidence checks	Education and training	TPM coordinator	Excel	TPM self-assessment	Get it
	TPM skills matrix template with annual training planFour-level skill matrix with quarter-circle symbols	Education and training	TPM coordinator	Excel	Education and training	Get it
	Training licence and certification expiry tracker (forklift, confined space, work at height)See which forklift, confined space and work at height licences have expired, which expire in 30, 60 or 90 days	Education and training	TPM coordinator	Excel	Education and training	Get it
	Training needs and curriculum matrix by Jishu Hozen stepSet the level each role needs for every training topic by Jishu Hozen step, record where people are	Education and training	TPM coordinator	Excel	Education and training	Get it
	KYT (Kiken Yochi Training) 4-round hazard prediction sheetRun the four-round KYT team talk before a job: find the hazards, mark the key ones, agree actions and set one target	Safety, health and environment	Operator, TPM coordinator	PDF A4	Safety, health and environment	Get it
	Lockout and isolation card with personal locks and energy point listOne card per machine: energy points with a photo each, the isolation steps from prepare to try-start	Safety, health and environment	Operator, TPM coordinator	PDF A4	Safety, health and environment	Get it
	Near-miss report and BBSO observation log (Excel)Log every near miss (Hiyari Hatto) with potential severity and occurrence	Safety, health and environment	Operator, TPM coordinator	Excel	Safety, health and environment	Get it
	Safety walk checklist and hazard register with risk removedWalk an area on nine check groups, score every hazard before and after its control	Safety, health and environment	Operator, TPM coordinator	Excel	Safety, health and environment	Get it
	Safety, health and environment (SHE) pillar auditScore the safety, health and environment pillar on 24 evidence checks in 7 groups and see the weakest group	Safety, health and environment	Operator, TPM coordinator	Excel	Safety, health and environment	Get it
	Office process time map (touch time, wait time, loss)Map one office process step by step, split value-adding, required non-value and waste time	Office TPM	TPM coordinator	Excel	Office TPM	Get it
	Office TPM loss identification worksheetList recurring office and support losses by loss family, see the downtime and late orders they cause	Office TPM	TPM coordinator	Excel	Office TPM	Get it
	Office TPM pillar auditScore the office TPM pillar on 24 observable criteria in six groups and get the weakest group and an action list	Office TPM	TPM coordinator	Excel	Office TPM	Get it
	5S audit checklist (Excel) by area type, with score, radar and actionsRun the 5S audit checklist for a production line, workshop, stores, office or utility area: 25 checks, score	5S	Operator, JH leader, TPM coordinator	Excel	5S in TPM	Get it
	5S audit checklist with radar, weakest three S and zone historyScore a zone on 25 statements in a 5S audit checklist, see the radar and weakest three S, and keep each zone's history	5S	Operator, JH leader, TPM coordinator	Excel	5S in TPM	Get it
	5S audit report: score by S, weakest three S and first actionsTurn a 5S audit checklist into one A4 report: score by S	5S	Operator, JH leader, TPM coordinator	PDF A4	5S in TPM	Get it
	5S red tag cards (Seiri) and holding area sheet, printablePrint eight 5S red tags per A4 with reason, disposal, decision date and approver	5S	Operator, JH leader, TPM coordinator	PDF A4	Red tag system	Get it
	5S red tag holding area log (Excel): decisions, days in holding and value recoveredLog every red-tagged item from 5S sort, see how long it waits in the holding area for a decision	5S	Operator, JH leader, TPM coordinator	Excel	Red tag system	Get it
	Autonomous maintenance vs preventive maintenance task transfer matrix: which PM tasks move to operatorsDecide task by task which preventive maintenance work operators take over from the PM plan	Jishu Hozen	Operator, JH leader, TPM coordinator	Excel	Autonomous vs preventive maintenance	Get it
	Kaizen idea sheet: fill in and printWrite each Kaizen on one page: before, after, cause, countermeasure, yearly saving and the machines to copy it to	Kobetsu Kaizen	TPM coordinator, PM engineer	Excel	Kaizen sheet format	Get it
	Kobetsu Kaizen master plan template: loss reduction cascade (Excel)Cascade plant loss targets across the 16 losses into Kobetsu Kaizen (focused improvement) themes by quarter	Kobetsu Kaizen	TPM coordinator, PM engineer	Excel	Kaizen software	Get it
	P-M analysis worked example: chronic minor stoppage on a filler (4-page)Follow all eight P-M analysis steps on one chronic minor stoppage on a filler	Kobetsu Kaizen	TPM coordinator, PM engineer	PDF A4	P-M analysis	Get it
	Life-cycle cost calculator for new equipment: compare up to three bids on total costCompare up to three bids for new equipment on life-cycle cost: energy, spares, maintenance and lost production	Early equipment management	PM engineer, TPM coordinator	Excel	Early equipment management	Get it
	MP sheet format (maintenance prevention sheet) and lesson logLog lessons from running equipment as MP sheets, print any as a form with before and after sketches	Early equipment management	PM engineer, TPM coordinator	Excel	Early equipment management	Get it
	One point lesson examples pack: 9 filled OPL examples (PDF)Learn the one point lesson format from nine filled examples	Education and training	TPM coordinator	PDF A4	One point lesson	Get it
	Office 5S checklist and shared-drive auditScore desks, cabinets, shared-drive folders and email on the five S with 20 checks for Office TPM	Office TPM	TPM coordinator	Excel	Office TPM	Get it
	OEE data capture maturity assessment (Excel)Score OEE data capture on your lines in 15 questions and get your level, from Paper to Connected	OEE, losses and KPIs	PM engineer, TPM coordinator	Excel	OEE software	Get it
	OEE gap value calculator: hours, parts and money recovered by lossTurn the gap between current and target OEE into productive hours, good parts and money a year	OEE, losses and KPIs	PM engineer, TPM coordinator	Excel	OEE calculator	Get it
	OEE gap value report: one-page A4 report with the loss splitSee on one A4 what closing your OEE gap is worth: hours, parts and money a year by loss, and the loss to close first	OEE, losses and KPIs	PM engineer, TPM coordinator	PDF A4	OEE calculator	Get it
	OEE improvement plan template: loss to pillar to action (Excel)Improve OEE by mapping each big loss to the pillar and method that removes it	OEE, losses and KPIs	PM engineer, TPM coordinator	Excel	Improve OEE	Get it
	Six big losses calculator: from planned time to OEETurn the minutes lost to the six big losses into the waterfall to OEE, the biggest loss and the pillar to start from	OEE, losses and KPIs	PM engineer, TPM coordinator	Excel	Six big losses	Get it
	TPM before and after benchmarkCompare a pilot before and after on the same definitions	OEE, losses and KPIs	PM engineer, TPM coordinator	Excel	TPM KPIs	Get it
	TPM KPI dashboard (PQCDSM): OEE, MTBF, MTTR, cost, delivery and safetyTrack OEE, MTBF, MTTR, cost per unit, on-time delivery, safety and fuguai closure monthly against targets	OEE, losses and KPIs	PM engineer, TPM coordinator, Plant Head	Excel	TPM KPIs	Get it
	TPM metric dictionary and definition decisionsTwenty-one TPM metric definitions, including fuguai closure, BM / PM ratio, cost per unit and OTIF	OEE, losses and KPIs	PM engineer, TPM coordinator	Excel	TPM KPIs	Get it
	Autonomous maintenance step 2 contamination sources and hard-to-access places log, with CIL time studyLog every contamination source and hard-to-access place found in autonomous maintenance step 2	TPM programme	TPM coordinator, Plant Head	Excel	Autonomous maintenance step 2	Get it
	Chokotei (minor stop) study sheet (PDF)Count minor stops for 60 minutes by symptom and time each one	TPM programme	TPM coordinator, Plant Head	PDF A4	Downtime reason codes	Get it
	Chokotei (minor stop) study tally (Excel)Tally a 60-minute minor stop observation by symptom	TPM programme	TPM coordinator, Plant Head	Excel	Downtime reason codes	Get it
	Cost of poor quality calculator for rejects, rework and complaintsPut a monthly rupee value on rejects, rework and complaints for each defect	TPM programme	TPM coordinator, Plant Head	Excel	Quality maintenance	Get it
	Customer complaint register and 8D report trackerRun every customer complaint through D1 to D8 with dates, and see open 8Ds, days to containment and days to close	TPM programme	TPM coordinator, Plant Head	Excel	Quality defect management software	Get it
	Digital TPM roll-out playbook: the entire TPM in 6 to 8 weeks with Excel uploadsPlan the entire TPM going live in 6 to 8 weeks: week-by-week focus, Excel uploads	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM implementation	Get it
	General inspection (Sotenken) kit for autonomous maintenance step 4: six modules, inspection points and operator testsTeach autonomous maintenance step 4, general inspection (Sotenken), one module at a time with inspection points	TPM programme	TPM coordinator, Plant Head	PDF A4	Autonomous maintenance steps 4 and 5	Get it
	Group TPM steering committee pack: league table, award plan and decisions for the boardRun the quarterly group TPM review for up to ten plants: group PQCDSM, a league table	TPM programme	TPM coordinator, Plant Head	Excel	TPM roles and responsibilities	Get it
	Group TPM steering committee: 90-minute agenda and decision recordRun the group TPM steering committee in 90 minutes each quarter	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM roles and responsibilities	Get it
	Hinshitsu Hozen 10-step roadmap for quality maintenanceSee the 10 steps of Hinshitsu Hozen (quality maintenance) on one wall chart, with each step's output	TPM programme	TPM coordinator, Plant Head	PDF A4	Quality maintenance	Get it
	Hiyari Hatto near-miss pocket card print pack (A6, 4 per)Print Hiyari Hatto (near-miss) cards for every line: what happened, who could be hurt, severity and quick fix	TPM programme	TPM coordinator, Plant Head	PDF A4	Safety, health and environment	Get it
	Jishu Hozen circle activity board (katsudo-ban)Give every Jishu Hozen (autonomous maintenance) circle one A3 board for members, step, tag graph	TPM programme	TPM coordinator, Plant Head	PDF A3	Jishu Hozen	Get it
	Jishu Hozen step 0 and step 1 kick-off pack (PDF)Start autonomous maintenance step 1 on time with a three-day run sheet, a six-item readiness check	TPM programme	TPM coordinator, Plant Head	PDF A4	Autonomous maintenance step 1	Get it
	Jishu Hozen step audit form (shindan, PDF, one page per step)Audit any machine with a one-page Jishu Hozen (autonomous maintenance) step audit form: scored criteria	TPM programme	TPM coordinator, Plant Head	PDF A4	Autonomous maintenance checklist	Get it
	Jishu Hozen step self-check: which step is your line really at?Find the Jishu Hozen (autonomous maintenance) step your line has really passed in twenty yes or no questions	TPM programme	TPM coordinator, Plant Head	PDF A4	Jishu Hozen	Get it
	Jishu Kanri circle KPI board (autonomous management, step 7) with targets, actuals and trendGive each Jishu Kanri (autonomous management) circle its own board: breakdowns, minor stops	TPM programme	TPM coordinator, Plant Head	Excel	Autonomous maintenance steps 6 and 7	Get it
	Multi-plant TPM maturity and OEE league table (group roll-up)Rank plants on TPM maturity and OEE, see what closing the gap to the best plant is worth, and which plant to copy	TPM programme	TPM coordinator, Plant Head	Excel	TPM self-assessment	Get it
	Plant Head monthly TPM review packRun the monthly TPM review on a correct PQCDSM scorecard, with pillar status, decisions and a one-page board extract	TPM programme	TPM coordinator, Plant Head	Excel	TPM KPIs	Get it
	QA matrix and rejection RCA template (Hinshitsu Hozen)Rank defects by where they are made and where they escape	TPM programme	TPM coordinator, Plant Head	Excel	Quality maintenance	Get it
	RCM worksheet template: failure mode and task selection (Excel)Pick the maintenance task for every failure mode in an RCM worksheet: condition-based, time-based, failure-finding	TPM programme	TPM coordinator, Plant Head	Excel	TPM vs RCM	Get it
	SAP PM and MM to TPM data-mapping workbookAgree which SAP PM and MM objects pass to your TPM system, in which direction and how often	TPM programme	TPM coordinator, Plant Head	Excel	TPM software SAP integration	Get it
	Skill certification practical test sheetCertify a skill for TPM training: observe each step against pass criteria, mark safety-critical steps	TPM programme	TPM coordinator, Plant Head	PDF A4	Education and training	Get it
	Skill certification test log (feeds the skills matrix)Log every practical skill test with its result, level awarded and re-test date	TPM programme	TPM coordinator, Plant Head	Excel	Education and training	Get it
	SMED changeover analysis worksheet (Excel)Cut the setup and adjustment loss: time every changeover element, split internal from external work	TPM programme	TPM coordinator, Plant Head	Excel	Six big losses	Get it
	The 16 major losses of TPM: wall chart with definitions, examples and how each is measuredKeep the 16 major losses of TPM on the wall: eight equipment, five manpower and three material and energy	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM glossary	Get it
	TPM award entries by country and year, 2006 to 2025 (Excel with charts)Use every JIPM award entry outside Japan from 2006 to 2025: pick a country, see counts by year and reuse the charts	TPM programme	TPM coordinator, Plant Head	Excel	TPM award winners by country	Get it
	TPM award ladder planner: which JIPM and CII category, in which yearPlan which JIPM award category and which CII certificate to apply for, and in which year	TPM programme	TPM coordinator, Plant Head	Excel	TPM Excellence Award	Get it
	TPM award ladder: JIPM categories and CII certificates, planned year by yearPost the TPM award ladder on one A4: JIPM categories and CII certificates with planned year	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM Excellence Award	Get it
	TPM award mock assessment (shindan) pack: checks by area, floor walk route and scorePrepare for the TPM Excellence Award: score 11 areas on observable evidence	TPM programme	TPM coordinator, Plant Head	Excel	TPM Excellence Award	Get it
	TPM Excellence Award readiness tracker: evidence by pillar, results and award categoryEvidence tracker for the TPM Excellence Award: 11 areas, prompts by pillar, results trend and a mock shindan	TPM programme	TPM coordinator, Plant Head	Excel	TPM Excellence Award	Get it
	TPM kick-off presentation for the plant team (15 editable slides)Launch TPM with your plant team using 15 editable slides: why we start, the eight pillars, 16 major losses	TPM programme	TPM coordinator, Plant Head	PowerPoint	TPM roles and responsibilities	Get it
	TPM loss profile cards by industry: process, automotive, food, pharma, paper, metalsPick the first TPM pillar for your industry: loss profile cards for process, automotive, food, pharma	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM by industry	Get it
	TPM maturity assessment with pillar radar and 90-day planScore a TPM self-assessment across twelve areas and get your maturity band, a pillar radar	TPM programme	TPM coordinator, Plant Head	Excel	TPM self-assessment	Get it
	TPM maturity report: radar, band, lowest three areas and 90-day planReport your TPM self-assessment in two pages: radar by area, your band, the three lowest areas with a first step each	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM self-assessment	Get it
	TPM policy and targets workbook: PQCDSM targets by pillar, with the cascade from plant to areaWrite the plant TPM policy, set a baseline and three-year target for each PQCDSM indicator	TPM programme	TPM coordinator, Plant Head	Excel	TPM implementation	Get it
	TPM policy and targets: notice board sheetPut the TPM policy on the notice board: the plant aim	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM implementation	Get it
	TPM ROI calculator: what OEE points are worth in your plantSee what 5 OEE points are worth in your plant: the yearly value of +1, +5 and +10 points and the payback on your cost	TPM programme	TPM coordinator, Plant Head	Excel	Total Productive Maintenance	Get it
	TPM skills matrix notice board (or 2 x)Post the TPM skills matrix at the line: four levels on A3 or two A4 sheets	TPM programme	TPM coordinator, Plant Head	PDF A3	Education and training	Get it
	TPM software demo-day script: 11 tasks to run on your own dataCompare TPM software fairly: eleven tasks to run live on your own equipment list, with timings	TPM programme	TPM coordinator, Plant Head	PDF A4	TPM software buyer's guide	Get it
	TPM software roll-out plan: the entire TPM in 6 to 8 weeksSee the entire TPM going live in 6 to 8 weeks on one page: Excel uploads, configuration, pillars, training	TPM programme	TPM coordinator, Plant Head	PDF A4	MaintWiz TPM software	Get it
	TPM software roll-out plan: the entire TPM in 6 to 8 weeks (Excel)Plan the entire TPM roll-out in 6 to 8 weeks with Excel uploads: tasks by week	TPM programme	TPM coordinator, Plant Head	Excel	MaintWiz TPM software	Get it
	TPM templates and tools library indexEvery free TPM template grouped by pillar, with a start-here list for a plant review and a direct link and QR code	TPM programme	TPM coordinator, Plant Head, Buyer	PDF A4	TPM	Get it
	Why-why analysis format (PDF)Print the why-why analysis format: a 5W1H header, three why chains	TPM programme	TPM coordinator, Plant Head	PDF A4	P-M analysis	Get it
	Why-why analysis format (Excel) with Gemba verificationAnalyse a chronic failure with parallel why chains, verify each why at the Gemba (shop floor) and catch chains that	TPM programme	TPM coordinator, Plant Head	Excel	P-M analysis	Get it
	Digital TPM guide: what a digital TPM system must do (white paper)What a CMMS must hold for each TPM pillar, and how MaintWiz rolls it out in 6 to 8 weeks	TPM software	Buyer, Plant Head	PDF A4	TPM digital transformation	Get it
	Excel to TPM software migration checklist (8-week plan)Plan the move from Excel to TPM software in eight weeks, from scope and master data to the parallel run and cut-over	TPM software	Buyer, Plant Head, TPM coordinator	Excel	TPM templates and tools	Get it
	TPM business-case workbookTurn downtime, output, maintenance cost and scrap into payback, IRR and a one-page board summary from your own figures	TPM software	Buyer, Plant Head	Excel	TPM software pricing	Get it
	TPM software cost planner (three-year)Compare the three-year cost of TPM software on your users, plants and services	TPM software	Buyer, Plant Head	Excel	TPM software pricing	Get it
	TPM software RFP template and vendor scorecard (42 weighted requirements)Weight 42 requirements, score up to five vendors, run a proof of concept on your own equipment list and read a ranked	TPM software	Buyer, Plant Head	Excel	TPM software buyer's guide	Get it

Template to module

When does each template become a MaintWiz module?

When registers outgrow a spreadsheet, MaintWiz, an AI CMMS built for TPM, holds the same records on one equipment list.

Upload your registers into MaintWiz: book a demo.

When should you move from spreadsheets to a system?

Start in the spreadsheet you have; MaintWiz loads your Excel lists through easy Excel uploads, so the work already done is kept when tags, audits or OEE outgrow it. Signs it is time to move: several areas keep separate copies, tags go overdue without anyone seeing, OEE is reported by hand with different definitions on each line, audits are scored on paper, or management wants one view across the plant. A migration checklist and a requirements scorecard help plan the move, and MaintWiz holds the same records, tags, audits and OEE on one equipment list once they outgrow Excel (TPM software).

FAQ

Frequently asked questions