TOTAL PRODUCTIVE MAINTENANCE AND RELIABILITY

PRACTICE EXAM
(Answers in Red ink)

• TOPIC 1: 8 pillars of TPM, faulty development, the basic condition, technical standards, overall equipment
efficiency, natural and forced deterioration and the ideal condition.
• TOPIC 2: F-Tags using Pareto Chart as well as using the defect map

I. Matching Type: Select from Column B the answer that matches the description found in
Column A by writing the letter of your choice found in Column B to the space provided before
the number in Column A. (20PTS)

COLUMN A COLUMN B
__D_1. It improves equipment and its components so that A. Predictive
preventive maintenance can be carried out reliably. Maintenance
__F__2. This pillar is geared towards developing operators to be B. Quality Maintenance
able to take care of small maintenance tasks. C. Task Certification
__B__3. It is aimed towards customer delight through highest Sheet
quality through defect free manufacturing. D. Corrective
__H__4. It is aimed to have trouble free machines and Maintenance
equipment producing defect free products for total customer E. Fuguai
satisfaction F. Autonomous
__A__5. This is a method in which the service life of important Maintenance
part is predicted based on inspection or diagnosis, in order to G. Defect Map
use the parts to the limit of their service life. H. Planned Maintenance
__I___6. It uses percentages and cumulative sums for each I. Pareto Chart
[Link] fails and/or repair time. J. Initial Clean
__G__7. Is a visual representation of the location of all F-tags.
__C__8. A spread sheet used to identify who is allowed to work
on each task.
__J___9. Is the first practical equipment task for every TPM
team
__E__10 Another term contamination or abnormalities

II. Enumeration (20 pts)

2. 5 Targets of TPM
1. P – productivity: minimum 80% OPE and 90% OEE
2. D – Delivery: achieve 100% success in delivering the goods as required by the customer
3. C – reduce manufacturing Cost (30%)
4. Q – Quality (0 defects)
5. S – Safety (0 accidents)
 TOTAL PRODUCTIVE MAINTENANCE AND RELIABILITY
PRACTICE EXAM
3. 5 knowledge required before the initial cleaning can begin
1. Know all potential hazards and how to neutralize them
2. Understand how the tool/machine works
3. Understand all the different areas within the tool
4. Know and understand all risk assessments and safe working procedures
5. Know how to use log sheets

4. 5 required data needed to be recorded to get best results from repair analysis
1. F-tag number
2. Time and date of failure
3. Initial failure symptoms
4. Time repair began
5. Time repair was completed

III. Essay:
1. Discuss the importance of Office TPM as one of the 8 pillars of TPM. (15 PTS)

• Bringing TPM to the “office” or administrative functions is necessary so to have the whole
organization working and understanding each other from the same page. In this pillar,
the objective is both to eliminate efficiency losses in the office and service areas and to
implement tools such as 5S in order to create an organized and efficient office
environment. This can be aimed at logistics, scheduling, HR, accounting, and other
areas of the plant administrative support. An example is co-locating groups that rely
heavily on cross-communication, e.g., planning and scheduling.

2. Discuss briefly how 3 of our 5 sense be used in testing equipment. (15 PTS)
• Sight: “see obvious areas of damage and contamination” - checking oil levels is one of
the visual monitoring activities. Lubricant issues such as oil contaminated with water or
other materials, badly degraded or oxidized oil, and excessive foaming, as well as other
machine conditions including excessive vibration, loose belts, loose drive chains and
loose or missing fasteners
• Hearing: “hear noises” - auditory inspections can be a sensitive tool for testing and
monitoring equipment. Like hearing unusual vibrations and noises, squealing and
whistling, motor speed irregularities, dripping, air leaking.
• Smell: one’s sense of smell is powerful and can be used to identify various unwanted
machine conditions and lubricant problems. common lubricant issues noticeable by
smell are certain types of contamination such as solvents, fuel, refrigerants and other
process chemicals. Slipping belts or overheated components will often present an
alarming smell that demands investigation.
 TOTAL PRODUCTIVE MAINTENANCE AND RELIABILITY
PRACTICE EXAM
3. What is fuguai? Discuss how should a Fuguai be recorded. (15pts)
• Fuguai is a Japanese word which means "abnormality", simply termed in TPM as "F-
tags" which are lables that attached to the contaminated area and are used to identify it.

Red or white labels are used and are labeled and numbered so that no possible
duplication would occur. These color-coded tags are used to identify the complexity of
the task.

Red tags = requires a degree of technical knowledge for a technician

F-tag log sheet used to record the data: date, tool area, F-tag ID, task description, etc.

4. Discuss two possible TPM causes for the F- tags and what would be the possible
cure for the possible causes. (15 PTS)
• Inadequate skill level: Because they are merely executing the job as they were instructed
to do it, the fault is frequently not totally attributable to the technician or operator.
However, it is possible that it is due to a lack of skill. For more complicated issues,
training must be more in-depth and based on proper procedures and detailed notes. For
all required tasks, the skill level should be confirmed.
• Design weakness: To save money, designers frequently make concessions in their
designs. This could mean that the optimal materials or mechanical arrangements aren't
always employed, which can lead to issues in a moving assembly.
Other possible explanations include systems that are overdesigned or are too
sophisticated for the goal.