Free template
TPM tag log
A TPM tag is a tag an operator hangs on a machine where they find an abnormality: a leak, a loose bolt, a hard-to-reach grease point, a source of dirt. Tags are sometimes called F-tags, from fuguai, the Japanese word for abnormality, and many sites use one color for problems operators can fix and another for maintenance. The tag log is the list behind the tags: what was found, where, who fixes it, and when it was closed, so no tag hangs for months. This template has a log with tag number, date, machine and location, the abnormality, its type from the seven types commonly used in TPM (minor flaw, basic condition not met, hard-to-reach place, source of contamination, source of quality defects, unneeded item, unsafe place), who found it, who fixes it, priority, action taken, closed date and days open, and a summary page by type, by who fixes it and by week. The Excel version works out status and days open, flags overdue tags, and counts by type, by who fixes it and week by week with a chart.
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
When to use it
When to use a TPM tag log
- During initial cleaning in step 1 of autonomous maintenance, when tags go up fast.
- Whenever operators tag abnormalities during daily CILR checks.
- To see whether maintenance can keep up with the tags raised.
- To find the machines and types of abnormality that keep coming back.
How to fill it in
- 1
Tag it where it is
Hang the tag on the machine at the abnormality, with a number, the date and what is wrong.
- 2
Log it
One row per tag: number, date, machine and location, the abnormality, its type and who found it.
- 3
Decide who fixes it
Operator if the team can fix it safely, maintenance if it needs a technician. Set a priority and a due date.
- 4
Fix and check
Write the action taken. Close the tag only when the fix is checked at the machine and the tag comes off.
- 5
Review each week
Open and overdue tags, tags open more than 30 days, and the balance of raised against closed.
- 6
Look for patterns
Many tags of one type on one machine point to the next improvement: a guard that traps dirt, a hard-to-reach point to move.
A filled-in example
Illustrative, not a benchmarkAn example: the first month of tags on a filling line (illustrative).
- 46 tags raised in the step 1 cleaning: 19 minor flaws, 11 sources of contamination, 8 hard-to-reach places, 5 basic conditions not met, 3 unsafe places.
- 28 fixed by operators within the week; 18 went to maintenance.
- At month end, 9 maintenance tags were still open, 4 of them past their due date.
- Seven of the contamination tags traced to one leaking seal on the product feed.
The unsafe places were fixed first, the seal was replaced, and the team asked for a maintenance day to clear the overdue tags before step 2.
Common mistakes
Tags nobody closes
A tag hanging for months teaches operators that tagging is pointless. Review the log weekly and close tags when fixed.
Closing without checking
Close a tag when the fix is checked at the machine, not when a work request is raised.
Everything to maintenance
Many tags are things the team can fix. Sending all of them to maintenance buries the ones that need a technician.
Counting tags as the goal
More tags is good early on, but the aim is fewer abnormalities, not a high tag count.
Download the template
Free to use: print it, copy it and edit it for your team. Enter your name and work email once to download.
Run this template in LeanSuite
In LeanSuite operators raise AM tags from the equipment's QR code during CILR checks, with a photo and a category, and rules route each tag to the right Area Lead or Maintenance partner with a due date.
In the lean glossary
FAQ
TPM tag log: common questions
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A shift handover sheet, a red tag log, a changeover checklist for one machine: if your team uses it on the floor, ask.