Implementation of Total Productive Maintenance | Benefits of TPM- Seven Steps Global

Implementation of Total Productive Maintenance | Benefits of TPM- Seven Steps Global




Total Productive Maintenance is well known in its abbreviated form – TPM has origins from Japan.  It is a well structured and scientific method refined with many iterations for getting the best and sustainable results. 
TPM is not only for machine intensive organizations. The approach and methodologies can be applied in the office environment also. 
When TPM methodology is implemented in an organization, it helps in improving the overall performance of a business by

Improving teamwork among the entire organization members – top management to the front line.

Making machines function with high reliability and consistent performance.

Improving machine availability through reduction of downtime and elimination of major losses which are defined elaborately according to TPM definitions.

Increased morale of the team members or front line members

Empowering and formally authorizing operators through TPM training and support to own and take pride in maintaining their own machines/ Equipment.
TPM is adopted company-wide and compliments many other parallel programs on Operational Excellence such as Lean Manufacturing, Total Quality Management, Theory of constraints, Six Sigma.  TPM is characteristically applied to equipment with emphasis on input and causes. TPM emphasizes the realization of ideal conditions to achieve the goal of Zero BAD which is total elimination of Breakdowns, Accidents, and Defects.
TPM has a very meaningful definition and philosophy which has expansion for each letter as follows:

T stands for Total which includes

Total involvement of members from top management to frontline members.

Total Elimination of losses, breakdowns, accidents, and defects

P Stands for Productive which means

The overall pursuit of improving production efficiency.. productivity or effectiveness

M stands for Maintenance which means

Maintaining the best performance of the equipment by ensuring the right conditions that are needed to get the best performance over its intended life span and beyond.

Key characteristics of TPM

TPM methodology is designed to achieve overall improvements in plants that are beyond machinery.

Jishu Hozen – JH or Autonomous Maintenance - AM which is a key differentiator from traditional Preventive maintenance PM is that operators or the frontline members take ownership of operations and basic maintenance of the equipment.
Equipment Management in the modern era began with Preventive Maintenance and improved further into productive maintenance.  This originated in the United States as PM and had a high focus on the maintenance department.
TPM is also called as productive maintenance with total participation involving every level and every function of the organization has helped Japanese companies to be in the top of the world in productivity, quality and cost advantages

The ultimate goal of TPM is Zero BAD

1

Zero breakdown
2

Zero Accident
3

Zero Defects

Key pillars of TPM are

1

Focussed improvements
2

Autonomous Maintenance
3

Planned maintenance
4

Early Management
5

Quality Maintenance
6

Skill training
7

Administrative and supporting functions.
8

Safety, Health, and Environment.
TPM helps in improving business results dramatically and enables safe, pleasant and productive workplaces by optimizing and improving teamwork between people working in different functions and roles.  TPM is also widely used in specialized process industries for achieving cost-effective operations where equipment reliability and need to operate for long hours without stoppage is important. In such areas, even a minor stoppage or breakdown of one single piece of equipment or component can result in plant shutdown.
Major credit for formulating and documenting the structured implementation of TPM goes to Japan Institute of Plant Maintenance – JIPM.  Knowledge and implementation experience of other methodologies such as Lean, TQM, Six Sigma, Lean Six Sigma can complement the implementation of TPM more effectively.

Evaluating the effective implementation of TPM involves

1

Assessing whether the organization has achieved policy and goals set before the launching of TPM
2

Whether the company has realized the intended benefits
3

How effectively topics are prioritized, action plans and quantitative targets have been pursued through continuous improvement activities.
4

Tangible benefits and intangible benefits realized.
Intangible benefits of implementing any program such as TPM, Lean, TOC, TQM or Lean Six Sigma should be considered important, It should be at least acknowledged.

Some of the intangible benefits of TPM are

Creating a safe working environment

Relaxed and meaningful workplace

Improved morale of people

Brand image and goodwill

Some of the initial steps of implementation of Structured TPM are

1

Set up a promotion office – TPM promotion office
2

Launch TPM introductory education to every team member
3

Form small group
4

Select group leaders
After this, each group needs to understand its present position and circumstances – as is the situation, identify the problems faced by its part of the organization, determine the ideal condition to aim for and opportunities available. With this, aim to set up consensus and aligning team thinking.
Even though TPM can be implemented with in-house resources, it has always worked by taking the help of experienced and reliable consultants of TPM from Industry.  TPM consultants from Seven Steps are veterans in their industry and have working and consulting knowledge of over 20 – 30 years each and combined experience of over 200 years.
Seven Steps Business Transformation Systems – SSBTS is a Consulting company of Seven Steps Group.  We have various specialties and have dedicated consultants for 
  • TPM Consulting
  • Lean Consulting for manufacturing,
  • Lean consulting for services
  • Lean consulting for hospitals
  • Lean consulting for retail
  • Lean consulting for supply chain and logistics
  • Lean consulting for construction
Where hands-on implementation support is needed, it is supported by the Seven Steps Business transformation system which is a consulting company specialized in the implementation of Lean manufacturing, Total productive Maintenance, Theory of Constraints, Six Sigma.
Our customers have got significant benefits in saving of Cost of poor quality apart from gaining increased market shared, reduced logistics/air shipment costs.
Some of the flagship training programs conducted at Seven Steps Academy of Excellence are:
Six Sigma Yellow Belt
Skill development program – Campus to Corporate – Precision Engineering
Lean Experimental Learning Programme

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