TPM Autonomous Maintenance Audit Guide & Checklists – Excel XLSX

TPM AUTONOMOUS MAINTENANCE (AM) AUDIT CHECKLIST TOOLKIT

Audit every step of your AM journey – from first wipe-down to full self-management – with one Excel workbook that scores itself.

This TPM Autonomous Maintenance Audit Checklist Toolkit is a professional resource designed to help organizations implement and sustain equipment care standards. Developed by Operational Excellence Consulting, the package includes a detailed Excel workbook and a PowerPoint user guide to facilitate systematic evaluations across the seven steps of maintenance. The toolkit features ten specialized audit sheets, an AM Maturity Dashboard, and a log for tracking progress over time. These materials are specifically updated to align with the JIPM 2026 TPM Excellence Award criteria, serving as both a diagnostic tool and a source of formal evidence for award applications. By utilizing automated scoring and customizable rubrics, the toolkit enables teams to identify improvement areas and transition toward full self-management of their machinery.

WHAT YOU GET

1. OEC_TPM_AM_Audit_Toolkit.xlsx – 13 tabs:

•  How to Use – scoring legend, the 7 Steps of AM at a glance, and a JIPM 2026 alignment briefing
•  Step 1 – 3, 5, 6 Audit Sheets – one sheet per AM step, each item scored against its own descriptive rubric (e.g. 5 = Cleaner than when passed … 1 = Dirty), with Section Subtotals and a Step Total that calculates automatically
•  Step 4-1 to 4-5 Audit Sheets – General Inspection broken out by equipment domain (Lubrication, Hydraulic & Pneumatic, Drive Systems, Electrical, Nuts & Bolts), with a readiness gate and a three-tier sign-off (Autonomous self-audit / Section Manager / Senior Executive)
•  AM Maturity Dashboard – every step's score, % and PASS/RETRY status in one view, with a live radar chart and a built-in JIPM eligibility check
•  Audit Log – a running history of every audit conducted, ready for trend tracking over time

2. OEC_TPM_AM_Audit_Guide.pptx – a 25-slide guide covering the 7 Steps of AM, how the checklists are aligned to JIPM's 2026 Award criteria, the anatomy of an audit sheet, how to conduct an audit (solo or as a team), and how to customize the checklists (the ECRS method) for your own equipment and industry.

Every audit item carries a dropdown score – auditors pick the descriptor that matches what they observed, and the sheet totals itself. No manual arithmetic, no version drift between auditors.

WHY THIS TOOLKIT

•  Built for the real audit, not just the paperwork. Every checklist item comes with a plain-language rubric (what "Bad" vs "Good" actually looks like on the floor), not just a blank Yes/No box.
•  Covers all 7 Steps, including the tricky ones. Step 4's five equipment-domain checklists and three-tier sign-off are notoriously hard to build from scratch – they're done for you.
•  Aligned to JIPM's 2026 Award criteria. The Dashboard flags the exact eligibility condition JIPM checks first: Step 3 complete, Step 4 active.
•  Fully editable. Add, remove or reweight audit items – the totals and dashboard recalculate automatically. Use the ECRS method in the guide to simplify for a plant that's new to TPM.

WHO IT'S FOR

•  TPM/AM pillar leaders and facilitators kick-starting or re-energizing Autonomous Maintenance
•  Plant managers and section heads preparing evidence for a JIPM TPM Excellence Award application
•  Maintenance and reliability engineers standardizing AM audits across multiple lines or plants
•  Lean/OpEx consultants who need a credible, ready-to-deploy AM audit tool for client engagements

FREQUENTLY ASKED QUESTIONS (FAQ)

Do I need Steps 1–7 audited every time? No – audit whichever step your line is currently working through. The AM Maturity Dashboard will show you the full profile once several steps have been scored.

Why does Step 4 have five separate sheets? JIPM's General Inspection step covers distinct equipment domains (lubrication, hydraulics/pneumatics, drive systems, electrical, fasteners) that need different site-audit checklists. Categories 1, 2, 3 and 5 are shared across all five; only the Site Audit section changes.

What happened to Step 7? JIPM doesn't require a separate Step 7 sheet. Keep re-using the Step 6 sheet – Step 7 (Full Self-Management) is confirmed once your score is sustained at 80%+ across repeated audits.

Can I change the scoring scale or the audit items? Yes. The workbook is fully editable – add, remove or reword items with the ECRS approach covered in the guide, and every total, subtotal and dashboard figure recalculates from whatever items remain.

Does this replace JIPM's own Self-Checklist? No – it's a working-level audit tool that builds the operational discipline and evidence trail JIPM's Self-Checklist and assessors look for. Use it alongside, not instead of, JIPM's official award documentation.

What software do I need? Microsoft Excel and PowerPoint (2016 or later recommended). The workbook uses standard formulas and dropdown data validation – no macros, no add-ins.

About Operational Excellence Consulting

Operational Excellence Consulting (OEC) is an elite Singapore-based management training and consulting firm specializing in Lean Thinking, Total Productive Maintenance (TPM), Total Quality Management, and Six Sigma. This identical toolkit represents the precise, battle-tested templates OEC's consultants deploy during formal corporate client engagements across Asia to build lasting continuous improvement capabilities.