TPM Pillars | Total Productive Maintenance | Implementation

What is TPM [Total Productive Maintenance]?

→ It is a systematic approach to maintain and improve the performance of the process, safety, product quality, and employee satisfaction.
→ The main focus of TPM is to maintain all machine is ready to work condition and also to avoid breakdowns and delays in manufacturing processes.
→ It emphasizes proactive and preventative maintenance to maximize the operational efficiency of the equipment.
→ It eliminates the gap between the roles of production people and maintenance people by empowering operators to maintain their equipment by themselves and it is a proactive process
→ So the TPM is all about the attitude from “I use, You maintain” to “I use, I maintain”.
→ Total Productive Maintenance is a Continuous Improvement program.
→ It works to prevent problems from occurring, instead of responding to problems.
→ It is a very important Lean Manufacturing Tool.

History:

→ Total Productive Maintenance was developed by Seiichi Nakajima in Japan between 1950 and 1970.
→ Therefore Seiichi Nakajima is known as the father of the TPM.
→ Nippondenso was the first company to get benefits by implementing.
→ TPM is all about the small group improvement activity.
→ The benchmark of Total Productive Maintenance is developed by (Japan Institute of Plant Maintenance) JIPM.
→ The Seiichi Nakajima developed the concept of 5 principles, later on, it was enhanced by JIPM with 8 principles/pillars.
→ This methodology is also a part of Lean Manufacturing. 

Objectives:

→ Improve the effectiveness of the machine
→ To train all staff in relevant skills
→ To achieve early equipment management
→ Higher plant availability
→ Higher Reliability
→ Increase the safety of personnel and a safe working environment
→ Better Quality Product or no defect generation
→ Increase the life cycle of a machine
→ Greater cost-effectiveness
→ No Breakdowns
→ Eliminate Small Stops or Slow Running

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The Working Principle of TPM:

→ Traditionally, maintenance departments have been responsible for maintaining the machine.
→ In the TPM_approach, all workers have to actively involved in maintaining the machine.
→ Employees are trained to maintain the machine and improve Overall Equipment Efficiency (OEE).
→ This is a foolproof system that prevents breakdowns and eliminates defects.
→ If any breakdown happens then it is quickly addressed, and the cause is eliminated by improving the equipment.
→ Implementation of 5S Methodology is the foundation of the successful implementation of TPM.

Eight Pillars of TPM:

→ It is mostly focused on proactive and preventive techniques for improving equipment reliability and they are mentioned below.

1. Autonomous Maintenance [Jishu Hozen]
2. Focused Improvement [Kobetsu Kaizen]
3. Planned Maintenance
4. Quality Management or Maintenance
5. Early Equipment Management
6. Education and Training
7. Administrative & Office_TPM
8. Safety, Health, and Environment

What is Autonomous Maintenance? [Jishu Hozen]

→ It allows operators to carry out directly simple maintenance works by themselves to prevent breakdowns and take faster action if a certain failure has been detected.
→ This is also known as a Jishu Hozen.
→ In Jishu Hozen the C-L-I-T Method is very famous.
→ The word CLIT stands for Cleaning, Lubrication Inspection, and Tightening.
→ It is one of the major activities of the operator before starting his daily work.
→ The purpose of this pillar is to provide training for each operator to maintain the machine by himself.
→ In this pillar, the development of operators to handle initial maintenance requirements and tasks which are regularly required to maintain smooth operations.
→ Hence the maintenance peoples can divert and spend time on more value-added activities.
→ In this concept focus on, each equipment operator is responsible, for maintaining equipment in good condition.
→ Jishu Hozen program's target is:
→ Proper management, and bring equipment return to its ideal condition by restoration and replacement.

Key Point for Jishu Hozen:

→ Educate employee
→ Implement C-L-I-T Method
→ Take Action on Counter Measure
→ General Inspection
→ Autonomous Inspection
→ Standardize the work

Benefits of Jishu Hozen:

→ Reduce the performance losses
→ Improve overall equipment effectiveness (OEE)
→ Improvement to employee engagement, confidence, and equipment ownership.
→ Responsibility is defined so the operators have clarity about their work
→ Gives operators greater “ownership” of their equipment.
→ Identifies emergent issues before they become failures.

What is Focused Improvement? [Kobetsu Kaizen]

→ In the Japanese Language, Focused Improvement is called as a "Kobetsu Kaizen".
→ Kobetsu kaizen means prioritizing the most important losses and eliminating them.
→ It is focused on improvement on the whole system with the cumulative effort of a team.
→ Their goal is to maximize the effectiveness and efficiency of the equipment and decrease the company's losses and waste.
→ Small groups of people work together for improvements.
→ Organizational complex issues can possible through the implementation of focused improvement steps, generally, this pillar_follows structured system support of the PDCA cycle to identify and eliminate issues in a systematic way.
→ This pillar_ensures that the manpower has the skills and motivation to identify and reduce wastes from their processes and systems.

Benefits of Focused Improvement:

→ Improving efficiency by reducing defects in product, processes, and system
→ Improving safety performance by reducing risk factors in processes by analyzing risk levels and appropriate actions
→ The focused improvement pillar_ensures that the approach is taken in consistent and repeatable to assure sustainability
→ Recurring problems are identified and resolved by cross-functional teams.

What is Planned Maintenance?

→ The purpose of this pillar is to improve the effectiveness of equipment and produce zero defective products.
→ This can be achieved by focusing on the preventive, breakdown, and corrective maintenance.
→ The reliability, maintainability, and performance are also improved by this activity.
→ We can plan our maintenance schedule with the help of measured failure rates.
→ This pillar_follows a well-defined process for equipment maintenance and the Goals are Zero break downs, to reduce MTTR (Mean Time To Repair) & Increase MTBF (Mean Time Between Failure).
→ That means to produce 100% product without any defect due to machine.

Benefits:

→ Reduction of the breakdowns and with minimum product defects.
→ Improve machine efficiency.
→ Improve Reliability and maintainability of the machine.
→ Significantly reduces instances of unplanned stop time.
→ The quality of the part is maintained,
→ Increase in production up-time,
→ Reduced cost of operations,
→ Reduced the cost of machine maintaining.

What is Quality Management?

→ The fundamental concept of Quality Management is to develop an error detection mechanism and error prevention mechanism into production processes.
→ Apply Root Cause Analysis Method like Fishbone Diagram or Why Why analysis method for finding out the root cause and apply preventive action to eliminate recurring sources of quality defects.
→ We can reduce costs by detecting defects at an early stage.
→ The process can be controlled by applying control mainly on man, machine, material, and method.
→ The aim is to prevent defect rather than it occurs and detect.
→ If defect prevention is not possible in that case we can think about the detection of the defect.
→ Zero breakdown leads to production without defect or also called zero quality defect.
→ By observing the variations of running machines can help us to prevent the defect from machine failure.
→ Everyone is responsible for maintaining optimal conditions and targets for zero defects.
→ Defects become a failure of the organization’s systems, not the fault of the operator.

Two Phases of Quality Management:

1. Quality Control or Reactive Approach
2. Quality Assurance or Proactive Approach

Benefits of Quality Management:

→ Quality Management reduces the Cost of Quality
→ It reduces the poor quality wastes and reworks
→ Customer complain reduce by improving the product's quality

What is Early Equipment Management?

→ Early Equipment Management (EEM) is a well-organized process and it guides for the design and manufacture of the machine.
→ It focuses on reducing the difficulties related to the operation and machine care activity.
→ Early Management aims to implement new products and processes with minimum development lead time and easy mass-produced.
→ The main goal is a defect-free product and zero breakdowns.
➨ Two main parts are
     ⇢ 1. Early Equipment Management
     ⇢ 2. Early Product Management
→ Both approaches focus on using the lessons from previous experiences to eliminate the potential failure modes during the planning, development and design stages.
→ New products must be designed as foolproof so that the product run can be smooth.
→ New machines must be designed for easier operations, changeover, and maintenance

Benefits:

→ Reduce the product and process setup lead time.
→ Improve Overall Equipment Effectiveness
→ Able to deliver mass product volume with good product quality.

Wha is the Training and Education pillar in TPM?

→ Training is the most important to achieving TPM_goal.
→ It applies to all operators, supervisors, and managers.
→ Operators develop skills to maintain the machine and identify emerging problems.
→ The operator learns techniques for proactive and preventative machine care activity.
→ Training and Education ensure that the staff is trained as per the required skillset.
→ The skill is identified by the managers and it helps in the successful deployment of TPM in line with the organization’s goals and objectives.
→ The goal of the Training and Education is to run a factory with trained and skilled manpower.

Different Levels of Skills:

→ Do not know.
→ Know the theory but cannot do.
→ Can do but cannot teach
→ Can do and also teach.

Benefits of Training and Education:

→ Increased skills and performance of all personnel.
→ Without training the human potential creates significant waste within an organization.
→ By training, we can have multi-skilled employees.
→ By training and education the operator and supervisor can do work with more efficiency, with effectiveness, and independently.

Wha is administrative and Office pillar in TPM?

→ This pillar is about to apply TPM techniques to administrative functions.
→ The purpose of this pillar is to achieve zero function losses, the establishment of efficient offices, and the implementation of service support functions for manufacturing processes.
→ Make all supportive functions to understand and apply the principles of lean in their own operations.
→ The TPM_principles can also be applied as stand-alone techniques to improve the efficiency of these supportive functions.
→ By implementing office TPM we can improve productivity, efficiency in the administrative functions.

Some of the major losses of this pillar:

→ Processing loss
→ Cost loss in some process such as procurement, accounts, marketing, sales leading to high inventories
→ Communication loss
→ Idle loss
→ Set-up loss
→ Accuracy loss
→ Non-availability of correct online stock status
→ Expenses on emergency dispatches/purchases etc...

Benefits:

→ Better utilized work area
→ Reduce repetitive work and inventory level of all products in the entire supply chain
→ Reduced administrative and overhead costs
→ Reduction in breakdown of office machine and customer complaints due to logistics.
→ We can reduce the expenses due to emergency dispatches/purchases

What is Safety, Health, Environment pillar in TPM?

→ This pillar is all about maintaining a safe and healthy working environment.
→ The target of this pillar is zero accidents, zero health damage, and zero fire.
→ So the workers must be able to perform their functions in a safe environment without any health risks.
→ By implementing this pillar, it eliminates potential health and safety-related risks.
→ This pillar ensures that all workers are working in a safe and accident-free work environment.
→ When workers are working in a safe environment then their attitude towards work changes and it increases productivity.
→ Each of these measures is aimed at improving the safety of the machines so as to have a more productive work-force.
→ We can create awareness among employees by various competitions like safety slogans, Quiz, Drama, Posters, etc.
→ By this activity we can improve related to safety can be organized at regular intervals.

Benefits of Safety, Health, Environment:

→ It provides a safe and accident-free working environment.
→ Safety, Health, and Environment pillar_create an efficient and effective work environment.
→ It improves employee's motivation.
→ In a safe environment, employees' attitudes towards work changes dramatically resulting in productivity, Quality, and Delivery Performance improvements.
→ The immediate benefits of implementation of this pillar are the prevention of accidents and incidents, environmental system failures, and financial costs saving due to containment, investigation, and compensation to the organization.
→ This can be enhancing sustainability in the organization.

Summary of TPM:

1. Autonomous Maintenance [Jishu Hozen]
→ Operators take care of equipment.
→ Operators feel responsible for their machines and it becomes more reliable for operation.

2. Focused Improvement [Kobetsu Kaizen]
→ Use of cross-functional teams for improvement activities.
→ Improves the problem-solving capabilities of the workers.

3. Planned Maintenance
→ The machine care activities scheduled using the historic failure rate of the machine.
→ Also, it is planned when production activities are less.

4. Quality Management
→ Quality deep-rooted with the machine to reduce defects.
→ Defect reduction & profit improvement.

5. Early Equipment Management
→ Design of new machine using the lesson learned from previous TPM activities.
→ The new machine achieves full potential in a shorter period of time.

6. Education & Training
→ Improvement of the skills and knowledge through training of all workers.
→ Employees gain the necessary skills to enable them to solve problems within the organization.

7. Health, Safety & Environment
→ Providing a healthy and safe working environment.
→ Elimination of harmful conditions & a healthy workforce.

8. TPM in the Office
→ The spread of the TPM principles to administrative functions within an organization.

👉 See Also:

➨ All Topics

➨ ISO 9001:2015

➨ 7 QC Tools

➨ Quality Core Tools like MSA, FMEA, APQP, SPC

➨ Six Sigma

➨ QA & QC Topics