OEE & TPM Services Assessment - Greendot Management Consultancy

Welcome to your OEE & TPM Services Assessment

Q1. What type of operation do you run?

A. Batch-based, low utilization

B. Semi-continuous (some equipment runs 24/7, others batch)

C. Continuous process but with frequent stops

D. Fully continuous, 24/7 operations

Q2. What is your average equipment uptime?

A. Less than 60%

B. 61-75%

C. 76-90%

D. More than 90%

Q3. Do you measure OEE (Availability × Performance × Quality)?

A. Never measured

B. Occasionally, rough estimates

C. Yes, but not regularly analyzed

D. Yes, measured & tracked daily/weekly

Q4. How much downtime is due to breakdowns per month?

A. More than 40 hours

B. 20-40 hours

C. 5-20 hours

D. Less than 5 hours

Q5. Do you have a preventive maintenance (PM) schedule?

A. No formal PM, only breakdown maintenance

B. Basic PM schedule, often skipped

C. PM schedule followed, but irregularly

D. Robust PM schedule, always followed

Q6. Do operators perform daily checks (autonomous maintenance)?

A. No, only maintenance team works on machines

B. Occasionally, but not consistent

C. Yes, partially done

D. Fully trained operators perform daily AM

Q7. How accurate is your spare parts & lubrication management?

A. No system, often shortages

B. Basic inventory, frequent stock-outs

C. Adequate control but manual

D. Well-managed, digital/ERP-controlled

Q8. What is your average equipment speed/utilization vs rated capacity?

A. Less than 60%

B. 61-75%

C. 76-90%

D. 90%+ consistently

Q9. How frequent are minor stoppages/idle running issues?

A. Very frequent, daily

B. Weekly basis

C. Rarely, once/twice per month

D. Almost never

Q10. How standardized are your changeover/setup practices?

A. No standard, high downtime

B. Some standards but inconsistently followed

C. Documented SMED, not optimized

D. Fully optimized quick changeovers

Q11. Do you analyze Six Big Losses in productivity (Breakdowns, Setups, Idling, Reduced Speed, Defects, Startup Losses)?

A. Never

B. Rarely, only breakdowns

C. Sometimes, not systematic

D. Yes, regularly tracked & improved

Q12. What is your defect/rejection rate?

A. More than 10%

B. 5-10%

C. 2-5%

D. Less than 2%

Q13. Do you use Root Cause Analysis for repeated defects/breakdowns?

A. Never

B. Occasionally

C. Frequently, but not documented

D. Always, documented & reviewed

Q14. How engaged are operators in TPM initiatives (5S, Kaizen, AM)?

A. Not involved

B. Occasionally involved

C. Moderately engaged

D. Fully engaged & trained

Q15. Does management review OEE & TPM progress regularly?

A. Never

B. Once/twice a year

C. Monthly reviews

D. Weekly/daily structured reviews

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