How is autonomous maintenance compliance calculated?

Compliance is checks done divided by checks due, where a check counts as done only when it was initialled on its own shift or day. Over several machines or weeks the template adds the checks first and then divides, never averaging percentages. In the example the six machines had 1,728 checks due over eight weeks and 1,596 done: 92.4 percent against a 95 percent target.

Why type the checks due instead of calculating them?

The checks due in a week depend on how many days and shifts the machine actually ran and which monthly points fell in that week. Counting the boxes on the week's check sheets is the honest number. The Weekly Checks sheet also shows the standard's checks per normal week for reference: 15 for a machine with one daily point and one point checked each shift on two shifts, five days.

What is the difference between operator, maintenance and safety tags?

An operator tag is a problem the team can fix with its own skills and tools, a maintenance tag needs a technician, parts or a stop, and a safety tag marks something unsafe that has to be made safe at once. Each tag type has its own days to close on Setup: 7, 21 and 2 days in the example. A maintenance tag hung on 2 September is due on 23 September and reads Overdue after that until it is closed.

How much operator time does the CILT standard take?

Each point's minutes per week are its time per check multiplied by how many times it is due in a normal week. A 10-minute daily clean on a five-day week is 50 minutes; a 1-minute gauge check each shift on two shifts is 10 minutes. The dashboard adds these up: about 659 minutes a week for the six example machines.

Does the template follow the seven steps of autonomous maintenance?

It supports the steps that run on standards and tags: the initial clean and tagging, countermeasures for contamination sources and hard-to-reach places (the Pareto shows which keep recurring), and the cleaning, inspection and lubrication standard with weekly compliance. It does not score step audits; use your own AM step audit alongside it.

Can I add more machines or abnormality types?

Yes. The Setup lists, the standard and both logs are Excel tables that grow as you type. The dashboard's by-machine, by-tag-type and Pareto blocks are sized to the example lists; the Method sheet explains how to extend them and the dashboard warns when a list is longer than its block.

Maintenance and Reliability

TPM Autonomous Maintenance Checklist Excel Template

Write each machine's clean, inspect, lubricate and tighten standard, count the checks done against the checks due every week, and follow every abnormality tag from the day it is hung to the day it is closed.

Overview

This TPM autonomous maintenance template is a working Excel tool for operators, team leaders and TPM coordinators who run Jishu Hozen on the shop floor. It ships with eight weeks of example data for a fictional flexible-packaging plant with six machines on two shifts, including a slitter whose back shift misses checks, a four-day week and a run of maintenance tags waiting past their target, so the dashboard tells a story on day one.

The CILT Standard sheet is the checklist itself: every point to clean, inspect, lubricate or tighten, the condition that counts as good, the method and tool, the frequency and the minutes it takes. The frequency list on Setup turns each point into checks and operator minutes per week, so you can see how much AM time a machine's standard asks for before you agree it. Each week the team leader counts the boxes due and the boxes initialled on the check sheets; the workbook gives missed checks, compliance and a status word against your own target.

Abnormality tags are logged with their type, the kind of abnormality found and a due date from the tag type's target days. Open tags read Overdue, Due soon or OK against the status date you type, and closed tags say whether they met their target. The dashboard shows weekly compliance against the target, the abnormality types that keep coming back in a Pareto, and roll-ups by machine and tag type. Compliance is checks done over checks due, the same on-time completion formula as the PM Compliance Rate calculator on this site.

What this template includes

CILT Standard sheet: one row per clean, inspect, lubricate or tighten point per machine with the standard in words, method and tool, frequency, minutes and who does it
Checks per week and operator minutes per week for every point, from a frequency list you set for your own shift pattern
Weekly Checks log with checks due and done per machine, missed checks, compliance, a status word against your target and the tags raised that week
Abnormality Tags log with tag type, abnormality type, due date from the tag type's target days, days open, Overdue, Due soon or Complete in words, and whether each tag closed on time
Check columns on every sheet that name the problem: done more than due, weeks not starting on Monday, closing dates out of step with status, duplicates and items missing from the Setup lists
Dashboard with machine and date filters, KPI tiles for compliance, missed checks, open and overdue tags, a compliance-by-week chart and a Pareto of abnormality types
Roll-ups by machine (points, AM minutes, compliance, tags), by week and by tag type
Method sheet with every formula and a Verify sheet that re-checks them against an independent reference and the PM Compliance Rate calculator

Suggested use case

Use it to launch or sustain autonomous maintenance on a line: agree the CILT standard with the operators, review compliance and open tags in the weekly AM meeting, and show where contamination and lubrication problems keep coming back.

How to use it

On Setup, set the status date and your compliance target, then list your machines, check frequencies with how many times each is due in a normal week, abnormality types and tag types with their days to close.
On CILT Standard, write one row per point with the operators at the machine: where, what good looks like, how, how often and how long.
Every week, add one row per machine on Weekly Checks with the checks due and the checks done from that week's check sheets.
Log each abnormality tag on Abnormality Tags when it is hung, and close it with the date when the fix is checked; fix anything a Check column reports.
Move the status date forward and review the Dashboard, filtering by machine or by dates.

Frequently Asked Questions

How is autonomous maintenance compliance calculated?: Compliance is checks done divided by checks due, where a check counts as done only when it was initialled on its own shift or day. Over several machines or weeks the template adds the checks first and then divides, never averaging percentages. In the example the six machines had 1,728 checks due over eight weeks and 1,596 done: 92.4 percent against a 95 percent target.
Why type the checks due instead of calculating them?: The checks due in a week depend on how many days and shifts the machine actually ran and which monthly points fell in that week. Counting the boxes on the week's check sheets is the honest number. The Weekly Checks sheet also shows the standard's checks per normal week for reference: 15 for a machine with one daily point and one point checked each shift on two shifts, five days.
What is the difference between operator, maintenance and safety tags?: An operator tag is a problem the team can fix with its own skills and tools, a maintenance tag needs a technician, parts or a stop, and a safety tag marks something unsafe that has to be made safe at once. Each tag type has its own days to close on Setup: 7, 21 and 2 days in the example. A maintenance tag hung on 2 September is due on 23 September and reads Overdue after that until it is closed.
How much operator time does the CILT standard take?: Each point's minutes per week are its time per check multiplied by how many times it is due in a normal week. A 10-minute daily clean on a five-day week is 50 minutes; a 1-minute gauge check each shift on two shifts is 10 minutes. The dashboard adds these up: about 659 minutes a week for the six example machines.
Does the template follow the seven steps of autonomous maintenance?: It supports the steps that run on standards and tags: the initial clean and tagging, countermeasures for contamination sources and hard-to-reach places (the Pareto shows which keep recurring), and the cleaning, inspection and lubrication standard with weekly compliance. It does not score step audits; use your own AM step audit alongside it.
Can I add more machines or abnormality types?: Yes. The Setup lists, the standard and both logs are Excel tables that grow as you type. The dashboard's by-machine, by-tag-type and Pareto blocks are sized to the example lists; the Method sheet explains how to extend them and the dashboard warns when a list is longer than its block.