100+ Total Productive Maintenance (TPM) SOPs (Excel XLSX)

BENEFITS OF THIS EXCEL DOCUMENT

1. Provides a complete, ready-to-use framework for building a world-class Total Productive Maintenance system across all 15 TPM pillars.
2. Enables your organization to standardize maintenance, safety, quality, and improvement processes with over 100 professionally structured TPM SOPs.
3. Delivers an easy-to-implement foundation for boosting reliability, reducing downtime, and driving sustainable continuous improvement.

TPM EXCEL DESCRIPTION

This product (100+ Total Productive Maintenance [TPM] SOPs) is an Excel template (XLSX), which you can download immediately upon purchase.

Curated by McKinsey-trained Executives

Boost Reliability, Slash Downtime & Transform Your Factory With 100+ Ready-Made Total Productive Maintenance (TPM) SOPs – Fully Editable Excel Template

If you're serious about driving world-class equipment reliability, achieving breakthrough OEE improvements, and building a zero-loss, zero-defect, zero-accident culture, this 100+ Total Productive Maintenance (TPM) SOP Package is the ultimate toolkit your operation has been missing.

This comprehensive Excel-based TPM SOP library gives you instant access to professionally structured, ready-to-use Standard Operating Procedures covering all 15 TPM pillars. Whether you're launching TPM for the first time or elevating a mature TPM program to the next level, this package cuts months of development time and removes all the guesswork.

Perfect for manufacturers, maintenance teams, TPM pillars, consultants, auditors, trainers, and improvement leaders who demand fast, consistent, and sustainable TPM implementation.


Why This TPM SOP Package Is a Game Changer

✔ 100+ fully editable SOPs – plug-and-play templates ready for immediate deployment
✔ Covers Autonomous Maintenance, Planned Maintenance, Quality Maintenance, Kobetsu Kaizen, Office TPM, SHE, Training, 5S, Energy, Inventory, Governance, and more
✔ Designed to improve equipment uptime, reduce maintenance cost, and strengthen loss elimination
✔ Structured for audits, certifications, and compliance (ISO, IATF, JIPM)
✔ Ideal for creating your own TPM handbook, training material, or digital maintenance system
✔ Saves hundreds of hours of SOP writing and formatting

If you want a lean, disciplined, world-class manufacturing system, this bundle gives you the tools to make it happen – fast.


# Complete List of TPM SOPs Included (All in Excel, Fully Editable)

Cluster 1: Autonomous Maintenance SOPs
Cleaning and Inspection SOP
Lubrication Management SOP
Tightening and Fastening SOP
Minor Adjustment SOP
Visual Inspection Standardization SOP
Equipment Abnormality Tagging SOP
Initial Cleaning Checklist SOP
Operator Routine Maintenance SOP
Autonomous Maintenance Level-Up SOP
Daily Autonomous Maintenance Record SOP

Cluster 2: Planned Maintenance SOPs
Preventive Maintenance Scheduling SOP
Predictive Maintenance SOP
Condition Monitoring SOP
Breakdown History Analysis SOP
Maintenance Work Order SOP
Maintenance Resource Planning SOP
Equipment Downtime Recording SOP
Spare Parts Management SOP
Maintenance Calibration SOP
Maintenance Audit SOP

Cluster 3: Focused Improvement (Kobetsu Kaizen) SOPs
Loss Identification SOP
Root Cause Analysis (RCA) SOP
Pareto Analysis SOP
Fishbone Diagram SOP
5-Why Analysis SOP
Small Group Improvement SOP
Improvement Project Management SOP
PDCA Cycle SOP
Kaizen Suggestion Evaluation SOP
Loss Cost Calculation SOP

Cluster 4: Quality Maintenance SOPs
Quality Defect Mapping SOP
Poka-Yoke Implementation SOP
In-Process Quality Check SOP
Control Plan Development SOP
Quality Data Collection SOP
Quality Loss Analysis SOP
Standardization of Inspection SOP
Error-Proofing Verification SOP
Supplier Quality Interface SOP
Defect Trend Analysis SOP

Cluster 5: Equipment and Process Design SOPs
Maintainability Design SOP
Reliability-Centered Design SOP
Safety Integration in Design SOP
New Equipment Commissioning SOP
Process Capability Verification SOP
Standardization of Equipment SOP
Design for Lubrication SOP
Layout Optimization SOP
Early Equipment Management SOP
Design Change Control SOP

Cluster 6: Safety, Health & Environment SOPs
Machine Lockout/Tagout SOP
Personal Protective Equipment SOP
Emergency Response SOP
Fire Safety Inspection SOP
Hazard Identification and Risk Assessment SOP
Chemical Handling SOP
Waste Management SOP
Noise and Vibration Control SOP
Safety Audit SOP
Environmental Monitoring SOP

Cluster 7: Training & Education SOPs
TPM Training Matrix SOP
Skill Gap Analysis SOP
OJT (On-the-Job Training) SOP
TPM Awareness Training SOP
Cross-Functional Training SOP
Competency Certification SOP
Refresher Training SOP
TPM Skill Evaluation SOP
Training Feedback SOP
Training Records Management SOP

Cluster 8: Office TPM SOPs
Administrative Process Mapping SOP
Document Control SOP
Data Entry Accuracy SOP
Office Equipment Maintenance SOP
Digital File Management SOP
Procurement Process Optimization SOP
Energy Use Monitoring SOP
Communication Flow SOP
Office Waste Reduction SOP
5S in Office SOP

Cluster 9: 5S & Visual Management SOPs
Sort (Seiri) SOP
Set in Order (Seiton) SOP
Shine (Seiso) SOP
Standardize (Seiketsu) SOP
Sustain (Shitsuke) SOP
Visual Labeling SOP
Floor Marking SOP
Cleaning Standard Chart SOP
Red Tag Area SOP
5S Audit SOP

Cluster 10: Measurement & Analysis SOPs
OEE Calculation SOP
Equipment Efficiency Monitoring SOP
Data Collection SOP
Loss Categorization SOP
Trend Analysis SOP
TPM KPI Dashboard SOP
Maintenance Cost Tracking SOP
Failure Mode Tracking SOP
Reporting Format SOP
Performance Review SOP

Cluster 11: Spare Parts & Inventory Management SOPs
Spare Parts Identification SOP
Inventory Replenishment SOP
Critical Spares List SOP
Vendor Evaluation SOP
Warehouse Layout SOP
Spare Parts Inspection SOP
Stock Rotation SOP
Scrap and Disposal SOP
Inventory Audit SOP
Spare Parts Cost Control SOP

Cluster 12: Energy & Utility Management SOPs
Compressed Air System Maintenance SOP
Boiler Operation SOP
Water Treatment SOP
Power Distribution Inspection SOP
Cooling Tower Maintenance SOP
HVAC Preventive Maintenance SOP
Energy Consumption Monitoring SOP
Steam Leak Detection SOP
Utility Loss Reduction SOP
Utility Equipment Calibration SOP

Cluster 13: Continuous Improvement & Auditing SOPs
TPM Audit SOP
Pillar Review SOP
Benchmarking SOP
Cross-Functional Team Review SOP
Annual TPM Plan SOP
Monthly Review SOP
Action Plan Tracking SOP
Management Review SOP
TPM Maturity Assessment SOP
Continuous Improvement Record SOP

Cluster 14: Autonomous Safety & Ergonomics SOPs
Ergonomic Risk Assessment SOP
Operator Posture Improvement SOP
Safety Observation SOP
Near-Miss Reporting SOP
Safe Tool Handling SOP
Workstation Design SOP
PPE Compliance Audit SOP
Safety Behavior Training SOP
Hazard Signage SOP
Safety Scorecard SOP

Cluster 15: TPM Administration & Governance SOPs
TPM Policy Deployment SOP
TPM Committee Formation SOP
TPM Roadmap Development SOP
Pillar Leader Role SOP
TPM Data Management SOP
TPM Communication SOP
TPM Budgeting SOP
TPM Reward and Recognition SOP
TPM Documentation Control SOP
TPM Progress Review SOP



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Source: Best Practices in TPM Excel: 100+ Total Productive Maintenance (TPM) SOPs Excel (XLSX) Spreadsheet, SB Consulting