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TPM Pillar 4 Deep-Dive Assessment

Focused Improvement Deep-Dive Assessment

Kobetsu Kaizen — JIPM Pillar 4

This deep-dive assessment examines your Focused Improvement practices across 26 detailed questions in 6 subcategories. Focused Improvement systematically eliminates chronic losses through cross-functional teams using structured problem-solving methodologies — attacking the losses that remain after AM and PM are established.

Unlike the main TPM assessment which covers all 8 pillars at a high level, this deep-dive provides a granular view of your Kaizen maturity — from loss identification through structured problem-solving to horizontal deployment and improvement culture.

26 questions across 6 subcategories · 20-25 minutes

  • ◆ 4.1 Loss Identification & Quantification (5 questions)
  • ◆ 4.2 Problem-Solving Methodology (5 questions)
  • ◆ 4.3 Kaizen Project Management (4 questions)
  • ◆ 4.4 Cross-Functional Team Effectiveness (4 questions)
  • ◆ 4.5 Standardization & Horizontal Deployment (4 questions)
  • ◆ 4.6 Improvement Culture & Suggestion System (4 questions)

Completed the main TPM assessment? This deep-dive builds on your results, providing a detailed breakdown of your Focused Improvement practices. Your main TPM Pillar 4 score gives you the overview — this assessment gives you the action plan.

Important Disclaimer: This assessment is a self-evaluation tool for educational and awareness purposes. Results do NOT constitute formal TPM certification or professional audit. Organizations seeking formal TPM implementation audits should engage qualified JIPM-certified professionals.

All answers are confidential. Your data is processed securely and never shared with third parties.

Company Information

Tell us about your organization so we can benchmark your results.

Subcategory 1 of 6 5 questions

4.1 Loss Identification & Quantification

Focus: Identifying and quantifying all 16 major losses using OEE loss structure, loss tree analysis, and data-driven prioritization to target improvement efforts.

1. Are all 16 major losses (8 equipment, 5 labor, 3 material/energy) systematically identified and quantified?

2. Is OEE measured on critical equipment with a clear breakdown into Availability, Performance, and Quality components?

3. Is a loss tree or waterfall analysis used to show the breakdown from theoretical capacity to actual output?

4. Is data-driven prioritization (Pareto analysis) used to select improvement projects?

5. Are losses quantified in financial terms to support the business case for improvement projects?

Subcategory 2 of 6 5 questions

4.2 Problem-Solving Methodology

Focus: Structured use of Why-Why analysis, PM Analysis, FMEA, A3, and DMAIC for chronic loss elimination — going beyond simple 5-Why to understand physical mechanisms.

6. Are structured problem-solving tools (Why-Why, PM Analysis, FMEA) used for chronic loss elimination?

7. Does root cause analysis go beyond symptoms to understand the physical mechanism of failure?

8. Are multiple problem-solving methodologies available and applied appropriately based on problem type and complexity?

9. Is problem-solving capability built through structured training and coaching rather than just providing tools on paper?

10. Are analysis results documented in a standardized format with evidence recorded at each analysis level?

Subcategory 3 of 6 4 questions

4.3 Kaizen Project Management

Focus: Formal project chartering with defined problem statements, measurable targets, team composition, timelines, and milestone tracking.

11. Are Kaizen projects formally chartered with a clear problem statement, measurable target, team, and timeline?

12. Are project milestones tracked with regular review meetings and management visibility?

13. Is project completion discipline maintained with results verified at 30/60/90 days post-implementation?

14. Is the Kaizen project portfolio managed with cumulative savings and ROI tracking?

Subcategory 4 of 6 4 questions

4.4 Cross-Functional Team Effectiveness

Focus: Teams including operators, maintenance, engineering, and quality with clear roles, structured meetings, and effective facilitation.

15. Are improvement teams cross-functional, including operators, maintenance, engineering, and quality with clear roles defined?

16. Do teams follow a structured meeting cadence with prepared agendas and documented actions?

17. Are team facilitation skills developed with dedicated facilitators or trained team leaders?

18. Does stakeholder engagement ensure improvement actions are adequately supported and resourced?

Subcategory 5 of 6 4 questions

4.5 Standardization & Horizontal Deployment

Focus: Locking in improvements through standard updates and systematically replicating solutions across similar equipment and processes.

19. Are improvements standardized through updates to AM standards, PM procedures, and operating procedures?

20. Is a horizontal deployment register maintained to track replication of improvements across similar equipment?

21. Is the horizontal deployment rate tracked with a target of greater than 80% of applicable improvements deployed?

22. Is before/after documentation created for all completed improvements?

Subcategory 6 of 6 4 questions

4.6 Improvement Culture & Suggestion System

Focus: Employee engagement in improvement activities, functioning suggestion system, recognition programs, and continuous improvement as everyone’s job.

23. Is there a functioning suggestion system where all employees can submit improvement ideas?

24. Is the suggestion review process effective with feedback to submitters and an implementation rate above 30%?

25. Is there a recognition program for improvement contributions at both individual and team level?

26. Is the improvement participation rate tracked with a target of all employees involved in at least one improvement per year?

Additional Context

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Assessment Complete!

Here are your Focused Improvement maturity results.

Overall Focused Improvement Maturity Score

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out of 5.0

Subcategory Performance

Subcategory Breakdown

Subcategory Score Maturity Gap to 4.2

Priority Improvement Areas

Recommended Resources

What’s Next?

A detailed report with personalized recommendations will be sent to your email shortly.

T
Main TPM Assessment

48 questions across all 8 TPM pillars
M
Maintenance Maturity

56 questions across 5 SMRP pillars

Questions? Contact us at info@reliox.ai