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Question 1. Which of the following best describes the original purpose of Total Productive Maintenance (TPM) when it was first introduced by Seiichi Nakajima? A) To replace all human operators with robots B) To eliminate all equipment downtime through autonomous activities C) To reduce inventory levels by implementing just‑in‑time production D) To focus solely on preventive maintenance tasks Answer: B Explanation: Nakajima created TPM to engage operators in daily equipment care, aiming to eliminate downtime by making maintenance a shared responsibility. Question 2. In the TPM philosophy, “Total” refers to which of the following concepts? A) Total cost reduction only B) Total involvement of all employees and all equipment C) Total automation of the production line D) Total reliance on external service providers Answer: B Explanation: “Total” emphasizes full participation of every employee and coverage of every piece of equipment in the maintenance system. Question 3. Which TPM pillar focuses on operators performing routine cleaning, lubrication, and minor adjustments? A) Kobetsu Kaizen B) Jishu Hozen C) Keikaku Hozen
D) Hinshitsu Hozen Answer: B Explanation: Jishu Hozen (Autonomous Maintenance) empowers operators to conduct daily upkeep tasks. Question 4. The primary goal of “Zero Defects” is associated with which TPM pillar? A) Hinshitsu Hozen (Quality Maintenance) B) Early Equipment Management C) Administrative TPM D) Safety, Health, and Environment Answer: A Explanation: Hinshitsu Hozen aims to achieve zero quality losses by controlling equipment and process variables. Question 5. Which of the following metrics is NOT a component of the OEE formula? A) Availability B) Performance C) Quality D) Cost Answer: D Explanation: OEE = Availability × Performance × Quality; cost is a separate metric.
Answer: B Explanation: “Seiton” means organizing tools and materials so they are in the right place. Question 9. Which of the following is the first step of the Seven Steps of Autonomous Maintenance? A) Establish cleaning and lubrication standards B) Initial cleaning (cleanup) using 5S C) General inspection D) Full autonomous maintenance Answer: B Explanation: The process begins with a thorough cleaning of the equipment to identify problem areas. Question 10. The “Why‑Why” analysis (5 Whys) is primarily used in which TPM pillar? A) Planned Maintenance B) Focused Improvement (Kobetsu Kaizen) C) Early Equipment Management D) Administrative TPM Answer: B Explanation: 5 Whys is a root‑cause tool frequently applied during focused improvement activities. Question 11. What is the main purpose of Early Equipment Management (EEM)? A) To train operators in autonomous maintenance
B) To integrate maintenance considerations during equipment design C) To schedule breakdown repairs quickly D) To reduce administrative paperwork Answer: B Explanation: EEM involves planning for maintainability, reliability, and safety at the design stage. Question 12. Which metric measures the average time between two consecutive equipment failures? A) MTTR B) MTBF C) OEE D) Availability Answer: B Explanation: Mean Time Between Failures (MTBF) quantifies reliability by measuring the interval between failures. Question 13. In TPM, the “Zero Accident” program is part of which pillar? A) Safety, Health, and Environment (SHE) B) Quality Maintenance C) Planned Maintenance D) Education and Training Answer: A
C) TPM eliminates the need for any scheduled maintenance. D) TPM focuses solely on equipment replacement. Answer: B Explanation: TPM expands responsibility to operators and embeds ongoing improvement, unlike traditional PM which is maintenance‑only. Question 17. In the OEE calculation, if Availability = 90%, Performance = 80%, and Quality = 95%, what is the OEE percentage? A) 68.4% B) 72% C) 80% D) 85% Answer: A Explanation: OEE = 0.90 × 0.80 × 0.95 = 0.684 → 68.4%. Question 18. Which tool is most appropriate for visualizing the frequency of different defect types? A) Fishbone Diagram B) Pareto Chart C) Gantt Chart D) Control Chart Answer: B Explanation: Pareto analysis orders defects by frequency, highlighting the most significant causes.
Question 19. The “Kaizen” concept in TPM primarily promotes: A) Large, one‑time capital investments B) Continuous, incremental improvements C) Immediate replacement of all old equipment D) Outsourcing all maintenance activities Answer: B Explanation: Kaizen focuses on small, ongoing improvements rather than massive, infrequent changes. Question 20. Which of the following is a key responsibility of top management in TPM implementation? A) Performing daily equipment cleaning B) Declaring TPM policy and providing resources C) Conducting root‑cause analysis on the shop floor D) Managing spare parts inventory Answer: B Explanation: Senior leadership sets the vision, allocates budget, and drives cultural change. Question 21. During the “Preparation” phase of TPM implementation, the first activity typically performed is: A) Conducting detailed equipment failure analysis B) Forming a TPM promotion committee C) Installing condition‑monitoring sensors
Question 24. The term “RCM” stands for: A) Rapid Change Management B) Reliability Centered Maintenance C) Resource Cost Minimization D) Real‑time Condition Monitoring Answer: B Explanation: Reliability Centered Maintenance is a systematic approach to determine optimal maintenance strategies. Question 25. Which of the following statements best describes “Zero Small Stops” as a TPM objective? A) Eliminate all equipment breakdowns lasting more than 30 minutes. B) Reduce minor interruptions that cause loss of production time. C) Stop all production during scheduled maintenance. D) Remove all operators from the production line. Answer: B Explanation: “Zero Small Stops” targets short, frequent stoppages that erode efficiency. Question 26. A “5 Whys” analysis performed on a recurring bearing failure resulted in the root cause being “inadequate lubrication schedule.” Which TPM pillar would address this finding? A) Autonomous Maintenance B) Planned Maintenance C) Early Equipment Management D) Safety, Health, and Environment
Answer: B Explanation: Adjusting lubrication frequency is a planned maintenance activity. Question 27. Which of the following is a typical output of the “Focused Improvement” (Kobetsu Kaizen) process? A) A new equipment design specification B) A reduction in one of the Six Big Losses C) A revised corporate financial statement D) An external audit report Answer: B Explanation: Focused improvement projects target specific loss reduction. Question 28. In TPM, a “Standard Work” document for autonomous maintenance typically includes: A) A list of all spare parts and their suppliers B) Step‑by‑step cleaning, inspection, and lubrication procedures C) A financial cost‑benefit analysis of equipment replacement D) A schedule of annual major overhauls Answer: B Explanation: Standard Work guides operators through daily maintenance tasks. Question 29. Which of the following best explains the difference between “Planned Maintenance” and “Predictive Maintenance”?
Answer: B Explanation: Administrative TPM applies lean tools to improve non‑manufacturing processes, such as paperwork flow. Question 32. In the context of TPM, “Life Cycle Cost (LCC)” analysis is primarily used during: A) Autonomous Maintenance training B) Early Equipment Management C) Daily equipment cleaning D) Safety incident investigation Answer: B Explanation: LCC evaluates total ownership cost from design through disposal, informing equipment selection. Question 33. Which of the following is NOT a typical element of a “One‑Point Lesson” (OPL) used in TPM training? A) A single, focused instruction on a specific task B) Detailed statistical analysis of production data C) Visual aids such as pictures or diagrams D) Step‑by‑step procedural guidance Answer: B Explanation: OPLs are concise, visual instructions, not extensive data analyses. Question 34. The “Gemba” workshop in TPM education focuses on:
A) Conducting virtual simulations of equipment failures B) Observing the actual workplace where the process occurs C) Designing new plant layouts in CAD software D) Auditing financial statements Answer: B Explanation: “Gemba” means “the real place,” emphasizing on‑site observation and learning. Question 35. Which of the following best defines “Mean Time To Repair (MTTR)”? A) Time between two consecutive failures B) Average time required to restore equipment after a failure C) Total downtime per month D) Percentage of planned maintenance work Answer: B Explanation: MTTR measures the average repair time, reflecting maintenance efficiency. Question 36. In TPM, the term “Zero Accidents” is most closely linked to which measurement? A) OEE B) Safety Incident Rate (SIR) C) MTBF D. Planned vs. Unplanned Work Ratio Answer: B Explanation: Zero Accidents aims to reduce the Safety Incident Rate to zero.
D) A financial forecast for next fiscal year Answer: A Explanation: Pareto analysis highlights the vital few causes that contribute most to the problem. Question 40. The “5S” step “Seiketsu” corresponds to: A) Sorting unnecessary items B) Setting items in order for easy access C) Standardizing cleaning and organization procedures D) Sustaining discipline through audits Answer: C Explanation: “Seiketsu” means standardizing the practices established in the first three S’s. Question 41. Which of the following statements about “Planned vs. Unplanned Work Ratio” is correct? A) A higher ratio indicates more reactive maintenance. B) The ratio is calculated as Planned Work ÷ (Planned + Unplanned). C) It is unrelated to TPM performance. D) It measures only safety incidents. Answer: B Explanation: The ratio compares planned maintenance effort against total maintenance work.
Question 42. In the TPM “Eight Pillars” model, which pillar directly addresses environmental impact? A) Safety, Health, and Environment (SHE) B) Early Equipment Management C) Quality Maintenance D) Administrative TPM Answer: A Explanation: SHE includes waste reduction, energy consumption, and compliance with environmental regulations. Question 43. Which of the following is the most appropriate tool to analyze why a machine repeatedly stops during the start‑up phase? A. Fishbone Diagram B. SMED analysis C. Start‑up loss KPI D. 5 Whys Answer: D Explanation: The 5 Whys helps drill down to the root cause of start‑up issues. Question 44. Which of the following best describes “Total Effective Equipment Performance” (TEEP)? A) A metric that includes scheduled downtime in the OEE calculation. B) The same as OEE but expressed as a percentage of total calendar time. C) A measurement of only the quality rate of production.
B) A long‑term strategic planning session. C) A financial audit of maintenance budgets. D) The installation of a new CNC machine. Answer: A Explanation: Kaizen Blitz (or rapid improvement event) focuses on quick, focused changes. Question 48. Which of the following statements about “Autonomous Maintenance” is FALSE? A) Operators are responsible for daily cleaning and inspection. B) It eliminates the need for any skilled maintenance technicians. C) It promotes equipment ownership by operators. D) It includes standardizing maintenance procedures. Answer: B Explanation: Autonomous Maintenance does not replace skilled technicians; it complements their work. Question 49. Which metric would you examine to assess the effectiveness of a training program for operators in autonomous maintenance? A) MTBF improvement after training B) Number of spare parts purchased C) Average energy consumption per shift D) Length of the annual maintenance budget Answer: A Explanation: An increase in MTBF indicates that operators are effectively maintaining equipment.
Question 50. In a TPM implementation, the “Master Plan” is primarily used to: A) Schedule daily cleaning tasks for each operator. B) Outline the roadmap, goals, and timeline for rolling out the eight pillars. C) Calculate the depreciation of equipment. D) Assign safety responsibilities to the HR department. Answer: B Explanation: The Master Plan provides a structured approach for the entire TPM rollout. Question 51. Which of the following is NOT a typical element of a “Root Cause Analysis” (RCA) in TPM? A) Fishbone diagram B) 5 Whys C. OEE calculation D) Failure Modes and Effects Analysis (FMEA) Answer: C Explanation: OEE measures performance; it is not a root‑cause analysis tool. Question 52. The “Maintenance Cost Ratio” is calculated as: A) Total maintenance cost ÷ Total production cost B) Total maintenance cost ÷ Total equipment value C) Total maintenance cost ÷ Total sales revenue D) Total maintenance cost ÷ Total operating hours
