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Ask: What is TPM management? Answer: In terms of management, TPM (Total Productive Maintenance) aims to improve the overall equipment effectiveness of an enterprise. It involves preventive maintenance across the entire production system, and is an activity of equipment upkeep and maintenance based on the participation of all employees. Q: What are the conditions for enterprises to successfully implement TPM? Answer 1) Full commitment and enthusiasm of top leadership, as well as strong support ； 2) Develop a proper promotion plan and implementation procedure for TPM ； 3) Establish an employee performance evaluation and incentive mechanism linked to rewards ； 4) Foster a strong TPM corporate culture. What are the key aspects of the basic philosophy of TPM? Answer: First, improving the physical condition of personnel; second, improving the physical condition of equipment; third, improving the overall condition of enterprises. What do the three “fulls” of TPM refer to? What is the relationship among the three “wholes”? Answer: The three “alls” refer to full efficiency, a whole-system approach, and participation from all staff ； Based on full staff participation, with the entire system as the vehicle, and overall efficiency as the goal. What are the traditional five pillars in the TPM advancement framework? What are the other 3 of the ordinary eight pillars? Answer: Self-maintenance, planned maintenance, individual improvements, MP activities, and education and training are the traditional five pillars. The ordinary eight pillars also include quality maintenance, indirect affairs, and safety and hygiene. Question: What are the three effective tools for TPM team activities? Answer: Activity boards, meetings (group regular meetings), OPL (One-Point Lessons). Question: What is the necessity of the TPM activity board in group activities? Answer: The activity board serves as a guide for group activities; through it, one can keep track of the progress of the activities. Question: What is the purpose of companies implementing TPM? Answer: (1) Standardized management of equipment ； (2) Achieve maximum efficiency of the equipment (long cycle time, highest overall efficiency OEE) ； (3) Both decision-makers and ordinary employees believe that the condition of the equipment is relevant to them ； (4) Improve the quality of all employees to create a positive cycle ； (5) Focus on proactive maintenance to gradually achieve zero accidents, zero defects, and zero failures ； (6) Reduce equipment maintenance and repair costs ； (7) Improve the quality of maintenance work ； (8) Maintain optimal spare parts inventory to meet the requirements of the equipment to the greatest extent possible. Q: What are self-maintenance activities? Answer: The activities carried out by the production and operation department to prevent equipment degradation. Question: What is the purpose of self-maintenance? Answer: Create the optimal conditions for equipment, tools, workplaces, and offices, and train expert-level technicians in production. Q: Definition of a defect? Answer: The cause of equipment that leads to losses such as failures or quality issues is called a defect. Q: What is the most basic task in equipment maintenance? Answer: Cleaning, lubrication, tightening, and leak sealing. Question: What are the inspection categories? Answer: Routine inspections, periodic inspections, special inspections, and precision inspections. Question: What are the main aspects of difficult areas? Answer: Difficult areas include: areas difficult to clean, areas difficult to inspect, areas difficult to work on, and areas difficult to lubricate. Q: What is a cleaning and inspection activity? Answer: Activities that involve cleaning and inspecting the site to identify any irregularities and make improvements or restorations. Question: What are the 5 senses in inspection? Q: What are the methods for carrying out initial cleaning tasks? A: Ask, smell, look, touch, listen Answer: Designate a person responsible for each device. While eliminating sources of contamination, identify the causes of any irregularities. During cleaning, many hard-to-clean areas will be encountered; therefore, it’s necessary to consider creating appropriate tools. Question: What is fixed-focus photography? Answer: It involves taking photos of the same equipment at the same location and from the same angle before and after the improvement, in order to compare the conditions before and after the improvement. Q: Why is it said that the malfunction was caused by human error? Answer: Ultimately, failures are caused by errors in people’s ways of thinking and behaviors. Q: What does “organizing activities” refer to? Answer: Clearly distinguish all items at the workplace into necessary and unnecessary items. Question: What is the purpose of the organizing activity? Answer: Remove unnecessary items, and store the necessary ones in designated locations that are easy to find and convenient to use. Question: What does the rectification campaign refer to? Answer: To make it easy to find and use necessary items, designate and label the storage locations and quantities, and store them neatly. Question: What is the method for rectification? Answer 1) Carry out the 3 fixes (fixed location, fixed volume, fixed quantity) activities ； 2) With the item status board, anyone can easily understand the current status of the items ； 3) Clear identification of zone lines. Question: What is the concept of a fixed point? Answer: It’s appropriate to place items in a designated location; they should be stacked in the correct place, meaning the location must be clearly marked. Q: What is the concept of volume adjustment? Answer: Determine the name of the item by specifying the container, posture, and color used for clear identification. Q: What is the concept of quantification? Answer: Clear indication of the specific quantity of the item (such as maximum and minimum amounts)/height. Q: In the 6S activities, what does “cleaning” refer to? Answer: Continuous cleaning activities are carried out to maintain a tidy and clean state. Question: What does cleaning refer to in the 6S initiative? Answer: Maintain a state of tidying, organizing, and cleaning. Q: When operating and maintaining the equipment, the “Ten-Step Operating Method” must be followed. What are the specific steps? Answer: Cleaning, lubrication, adjustment, tightening, and corrosion protection. Question: What are the “four no’s” that must be observed during equipment operation? Answer: Over-temperature, over-pressure, over-speed, and over-load are all not allowed. Question: What are the main contents of the “three good practices and four skills” that operators should master? Answer: Mihoshi: Manage equipment well, use it properly, and maintain it well ； Four capabilities: ability to use, maintain, inspect, and troubleshoot. Question: The management of equipment lubrication must strictly adhere to the “Five Fixed Points and Three Filtrations” system. What exactly does this system entail? Answer: The five fixes: fixing the person, the location, the quality, the quantity, and the time ； Three filtration steps: from the large oil storage tank to the on-site oil storage tank, from the on-site oil storage tank to the oil jug, and from the oil jug to the equipment fueling point. Question: Equipment maintenance must adhere to the principle of “three no-handovers”. What does “three no-handovers” mean? Answer: Do not hand over duties if quality standards are not met, if there are no maintenance records, or if safety and hygiene standards are not satisfied. Question: What is the purpose of TPM team activities? Answer: First, it is an activity that reconciles the desires and aspirations of enterprises and individuals, enabling enterprises to improve their performance and individuals to achieve satisfaction by reaching their goals and realizing their own pursuits ； Second is to leverage the role of leaders. Question: What is natural degradation? Answer: Natural degradation refers to the physical changes that occur in a device over time, even when it is used correctly, resulting in a decline in its initial performance. Question: What is forced degradation? Can forced degradation be controlled? Answer: Forced degradation refers to the situation where employees fail to carry out their tasks in the proper manner, thereby artificially causing degradation. If fuel is not added at the required points, or if it is added but in insufficient quantities or at intervals that are too long. Forced deterioration can be controlled. Question: How should the goals for group activities be set? Answer: The group’s goals should first be aligned with those of the company and the factory ； Team goals should be more specific ； More challenging goals to strive for ； The goals should be determined independently by the group members. Question: How to eliminate the losses existing in a company? Answer: First, identify the defects that are prone to causing losses in advance and eliminate them to prevent such losses from occurring ； Second, potential defects should be treated as actual defects, and efforts should be made to eliminate them. Question: What is the significance of self-maintenance? Answer: Maintenance activities involving all members of the TPM team are called “self-directed maintenance activities with full participation.” There are two meanings here: managing one’s own equipment oneself ； Become an expert-level operator of the equipment. Question: During self-maintenance activities, how do you manage your own equipment? Answer: It is capable of performing routine inspections, oiling, tightening, and simple replacement or repair of components on the equipment under its responsibility, as well as early detection of abnormalities and precision checks. Question: What skills are required to become an expert-level operator of equipment? Answer: The ability to detect device abnormalities ； The ability to take remedial actions in the event of abnormal phenomena ； Ability to determine criteria ； The ability to maintain equipment management. Question: What are the 6 major irrationalities in the initial cleaning phase of autonomous maintenance? Answer 1) Removal of microdefects and contaminants ； 2) Preparation of basic conditions ； 3) Identification of difficult areas ； 4) Identification of the source ； 5) Searching for items that are not needed or urgent ； 6) Identifying unsafe points: Ask, What is sorting? Answer: Organize all items at the future workplace, clearly distinguishing between necessary and unnecessary items. Place the necessary items in designated locations, while registering the unnecessary items to be stored in a storage area or disposed of. Question: What is rectification? Answer: Organize the necessary and usable items that are about to be sorted, storing them in a standardized manner. Clearly indicate where each item is located, what it is, and how much there is, so that anyone can understand it at a glance. Question: What is the purpose of cleaning? Answer: The purpose of cleaning is to eliminate potential psychological flaws from an environmental perspective, such as indifference, turning a blind eye, and ignorance, so that one can believe they are capable of doing what needs to be done well. What does 6S mean in TPM activities? Answer: Organize: keep what is needed and discard what isn’t ； Organization: Scientific layout for quick access ； Cleaning: Removing trash to beautify the environment ； Cleaning: Establish systems and ensure their thorough implementation ； Competence: Abide by rules and develop good habits ； Safety: Operate safely; life comes first ； Question: What are the 6 main aspects of the source? Answer: These include pollution sources, defect sources, failure sources, hazard sources, waste sources, and sources of defects. Ask: What is the purpose of the two-stage \"2step\" approach to identifying the source of the problem and the areas where difficulties exist? Answer: By improving the sources of problems and difficult areas, creating a comfortable working environment, reducing the workload on workers, and addressing the causes of failures and various losses, productivity can be improved. Question: What is planned maintenance? Answer: Planned maintenance is an activity aimed at improving equipment reliability through preventive repairs carried out with the full participation of the maintenance team. Question: What does 4W2H mean, which is often used in activities? Answer WHO: Who will do it ； WHEN: When to do it ； WHERE: Where to do it ； WHY: Why do this ； HOW: How to do it ； To what extent does “HOWMUCH/MANY” apply? Question: What is the visual board strategy? Answer: The visual board strategy refers to the standardization effort in inventory management methods that makes normal and abnormal conditions of stored items clearly visible, enabling visual management. Question: What is the initial cleaning activity in the first phase of TPM autonomous maintenance? Answer: The initial cleaning activities in the first phase of TPM’s autonomous maintenance involve cleaning the environment and equipment, while also identifying any unreasonable aspects; in other words, this cleaning process includes elements of inspection. Question: Why is it necessary to understand the structural functions of the equipment under one’s responsibility before carrying out cleaning tasks? Answer: Because only by getting to know one’s own equipment in advance of an event can one more effectively identify any issues, and at the same time prevent problems or accidents from occurring, thus ensuring safety. Question: What is the core content of the initial cleanup activities? Answer: Implement initial cleaning to identify any irregularities ； Improve the unreasonable aspects that have been identified. Question: What is the purpose of fixed-point photography? Answer 1) By comparing previous and current examples, the group can gain a sense of accomplishment and boost their confidence ； 2) When performing TOP diagnosis, it can be presented to supervisors. Question: What is the purpose of creating a standard document? Answer: To maintain the results of the activities and keep the site in its current state. Maintenance ensures that the site remains in good condition, preventing it from returning to its previous state during phase-specific activities. Question: What are the main aspects of the diagnosis in the first phase of autonomous maintenance? Answer 1) The condition of the items on site ； 2) Verify the management status of the movable panels ； 3) Staff situation. Question: What is the difference between cleaning in 6S and cleaning in the initial cleaning activities? Answer: Cleaning in 6S mainly refers to the cleaning of equipment and the surrounding area, while the initial cleaning stage involves identifying any unreasonable aspects. Question: What is OPL education? Answer: OPL is a one-point course, also known as “10-minute education.” It refers to an educational method in which a project is organized on a piece of paper and then used to provide 5–10 minutes of instruction to group members, aiming to address their questions. Education is mainly centered around points of doubt. Question: What outcomes should be achieved by carrying out activities to address the difficult areas in the second phase? Answer 1) There are fewer and fewer items in the activities ； 2) The cycle of group activities is getting longer and longer ； 3) The duration of each cleaning session is getting shorter. Question: What is the difference between creating a phase plan and a monthly plan? Answer: For phase plans, it’s not necessary to designate a responsible person for each task. Monthly plans should be detailed and specific, with designated owners for each task and set dates; try to avoid having tasks run from the beginning to the end of the month. Question: What is the depth of the Why-Why analysis for countermeasures to prevent recurrence? Answer 1) Technical reasons: design defects, manufacturing defects, installation defects until they occur ； 2) Management reasons: Are there standards? Are the standards sufficient? Is awareness of these standards vorhand? What is the ability to implement them? How is the implementation of these standards evaluated? Question: Briefly describe the relationship between failure, degradation, and recovery Answer: Deterioration is the process of gradually approaching failure ； Restoration is the process of returning to a normal state; during degradation, a failure occurs when the strength of an item is lower than the stress applied to it. Question: What is a 3M campaign? Answer: Preventive Maintenance (PM), Predictive Maintenance (PM), and Corrective Maintenance (CM) are collectively referred to as the 3M activities. Question: What is preventive maintenance? Answer: By conducting regular inspections, equipment is kept in a fault-free condition. Question: What is predictive maintenance? Answer: Utilize precision instruments to diagnose and analyze the condition of equipment, predict the degree of degradation, and carry out maintenance measures before equipment failures occur. Question: What is improved maintenance? Answer: Improvement activities carried out to enhance the reliability, maintainability, safety, etc. of equipment, regardless of whether there are any defects in it. Question: What is the core of the improved CM maintenance campaign? Answer: The key is to conduct thorough inspections to identify problems in the individual units, with an emphasis on improvement activities involving all employees. Question: What are the key points of a cleaning campaign? Answer: First of all, the cleaner must personally clean each area of the activity zone one by one ； Thoroughly clean the dirt ； During cleaning, the root cause of the contamination must be identified. Question: What should be noted during equipment cleaning and inspection? Answer: During cleaning and inspection, it is important to focus on: studying cleaning tools and developing them ； Carried out in parallel with countermeasures at the source of occurrence ； Determine the order of cleaning. Question: What does *inertia (competence) refer to in the 6S initiative? Answer: Be proficient in organizing, tidying up, cleaning, and ensuring safety, and be able to properly implement the relevant systems at any time. Question: What are the two main approaches to addressing pollution sources? Answer: One approach is source control; the other is protection to prevent the spread of pollution. Question: How can difficult cleaning sources be effectively resolved? Answer: There are mainly two approaches. One is to control the source, making those hard-to-clean areas less prone to contamination, such as by installing protective covers on the equipment ； Second, specialized cleaning tools are designed and developed to turn tasks that are difficult to clean into ones that are easy to clean. Should positive incentives or negative incentives be the main focus in TPM activities, and why? Answer: Positive incentives should be the main approach. Because people enjoy being praised and encouraged, and encouragement can help unleash one’s potential even more. Question: What elements need to be determined during equipment inspections? The areas to be inspected, the routes to follow, the frequency of inspections, the key parts that require attention, as well as the requirements regarding the content of the inspections, all need to be determined. Question: Briefly describe the sequence of cleaning activities? Answer 1) Before the cleaning activity: preparation, planning, investigation of the equipment to be cleaned, preparation of tools, and safety training ； 2) During the activity: conducting unreasonable searches ； 3) After the activity: Gather to separately record the issues found by each person, discuss and formulate countermeasures, summarize the problems that arose during this activity, and outline the preparations for the next one. Question: What is the purpose of creating a cleaning and inspection standard document? Answer: The purpose is to sustain the results of the activities and maintain the current state of the site. Through ongoing maintenance and management, it ensures that the site remains in good condition and prevents it from reverting to its previous state during the implementation phase of the activities. Question: What is the process for the rectification campaign? Answer 1) List of necessary items on-site is provided ； 2) Determine the storage location based on usage frequency ； 3) Fixed-point photography, position marking ； 4) Three-fix (fixed location, fixed volume, fixed quantity) management ； 5) Improve the establishment of implementation plans ； 6) Improved implementation. Question: What are the main contents of the 2step campaign centered around devices? Answer: Improvement activities targeting emission sources and difficult-to-treat areas, centered around thorough zero-leakage efforts; and activities aimed at ensuring simplicity and convenience in operational procedures. Ask what LCC is an abbreviation for, what its meaning is, and what specific aspects it includes Answer: LCC is the abbreviation for LifeCycleCost, which refers to the costs associated with a device throughout its lifetime ； It includes the total of all costs incurred during the device’s expected life cycle for its demonstration, development, production, use, maintenance, decommissioning and disposal, as well as material recycling. Why is TOP diagnosis conducted in TPM activities? Answer 1) The team presents opportunities to TOP to achieve results ； 2) Opportunities for TOP to motivate and reward the team. Question: What are the key points for implementing consolidation? Answer 1) The location where the items are stored should be easy to use ； 2) Improve the facilities at the storage location ； 3) Implement fixed-labeling for items ； 4) Standardized maintenance management. Question: Why is addressing the source of difficulties carried out as a separate phase? Answer: Because difficult-to-fix problem areas identified during the first phase of TPM autonomous maintenance are generally not easy to improve, it is necessary to investigate the causes, which takes some time; therefore, it is implemented as a separate phase. Question: What is the purpose of stage diagnosis? Answer 1) Show the process of group activities and the results achieved ； 2) Identify the existing shortcomings and areas that need improvement ； 3) Promote the implementation of TPM activities within the team, so as to enable the team to meet the requirements of that stage. What is the difference between OPL education and our traditional education today? Answer: Traditional education is one-way, whereas OPL education involves employees creating their own teaching materials and educating each other by explaining what they consider to be necessary; it is a two-way form of education.