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TPM Pillar 3 Deep-Dive Assessment

Quality Maintenance Deep-Dive Assessment

Hinshitsu Hozen — JIPM Pillar 3

This deep-dive assessment examines your Quality Maintenance practices across 24 detailed questions in 5 subcategories. Quality Maintenance establishes and maintains equipment conditions that prevent quality defects from occurring — shifting from inspecting quality into the product to building quality into the process.

Unlike the main TPM assessment which covers all 8 pillars at a high level, this deep-dive provides a granular view of your quality maintenance maturity — identifying how well your organization links equipment conditions to quality outcomes.

24 questions across 5 subcategories · 15-20 minutes

  • ◆ 3.1 Equipment-Quality Relationship Mapping (5 questions)
  • ◆ 3.2 Quality Condition Standards & Control (5 questions)
  • ◆ 3.3 Defect Analysis & Root Cause Investigation (5 questions)
  • ◆ 3.4 Error-Proofing & Defect Prevention / Poka-Yoke (4 questions)
  • ◆ 3.5 Statistical Process Control & Quality Monitoring (5 questions)

Completed the main TPM assessment? This deep-dive builds on your results, providing a detailed breakdown of your Quality Maintenance practices. Your main TPM Pillar 3 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 5 5 questions

3.1 Equipment-Quality Relationship Mapping

Focus: Understanding which equipment parameters affect which quality characteristics through systematic Q-M (Quality-Machine) matrix development.

1. Has a Q-M (Quality-Machine) matrix been developed that maps quality characteristics to equipment components, settings, and conditions?

2. Are quality-critical equipment parameters identified and documented for all key products and processes?

3. Is 4M analysis (Machine, Material, Method, Man) used to understand the sources of quality variation?

4. Are equipment condition changes (PM activities, breakdowns, adjustments) tracked and assessed for their impact on quality?

5. Do quality and maintenance teams jointly review equipment-quality relationships on a regular basis?

Subcategory 2 of 5 5 questions

3.2 Quality Condition Standards & Control

Focus: Defining and maintaining optimal equipment conditions for quality — specifying exact settings, tolerance ranges, measurement methods, and corrective actions.

6. Are quality condition standards defined for all quality-critical equipment parameters?

7. Do quality condition standards specify the target setting, acceptable tolerance, measurement method, and check frequency?

8. Do AM (Autonomous Maintenance) and PM (Planned Maintenance) routines include quality condition checks as standard elements?

9. Do out-of-tolerance conditions trigger immediate corrective action with a defined escalation path?

10. Are quality condition standards reviewed and updated based on defect data and process changes?

Subcategory 3 of 5 5 questions

3.3 Defect Analysis & Root Cause Investigation

Focus: Systematic analysis linking quality defects to equipment condition deviations using PM (Physical Mechanism) analysis and similar methodologies.

11. Is PM (Physical Mechanism) analysis used to trace quality defects back to equipment condition deviations?

12. Are chronic quality defects systematically investigated using cross-functional teams?

13. Do defect investigation results lead to permanent equipment condition countermeasures?

14. Is the quality defect database linked to equipment maintenance history for correlation analysis?

15. Are lessons learned from defect investigations shared and applied to similar equipment across the organization?

Subcategory 4 of 5 4 questions

3.4 Error-Proofing & Defect Prevention (Poka-Yoke)

Focus: Mechanisms that make it impossible or immediately detectable to produce defects — systematic assessment and implementation of error-proofing devices.

16. Is there a systematic poka-yoke opportunity assessment for all quality-critical process steps?

17. Are poka-yoke devices implemented that prevent errors or detect them before defects are produced?

18. Is poka-yoke effectiveness verified through regular testing and maintenance?

19. Are new equipment designs required to include built-in error-proofing (design-for-quality)?

Subcategory 5 of 5 5 questions

3.5 Statistical Process Control & Quality Monitoring

Focus: SPC deployment on quality-critical processes with control charts, reaction plans, process capability tracking, and real-time monitoring.

20. Is SPC deployed on quality-critical processes with control charts maintained in real-time?

21. Are reaction plans defined for out-of-control signals with immediate response procedures?

22. Is process capability (Cpk) tracked and improved for key quality parameters?

23. Are quality and maintenance databases linked for equipment-quality correlation analysis?

24. Is real-time quality monitoring integrated with equipment condition monitoring systems?

Additional Context

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Assessment Complete!

Here are your Quality Maintenance maturity results.

Overall QM 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