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Total Productive Maintenance Implementation

Updated on October 13, 2009

TPM Implementation 12 Steps

Total Productive Maintenance Implementation: 12 Steps
Total Productive Maintenance Implementation: 12 Steps

Step 1: Announce top management’s decision to introduce TPM

  • State TPM objectives in a company newsletter
  • Place articles on TPM in the company newspaper

 

Step 2: Introductory education campaign

  • Seminars for managers
  • Slide presentations for all employees

 

Step 3: TPM Promotion

  • Special committees at every level to promote TPM
  • Newsletters
  • Articles
  • Videos
  • Posters

 

Step 4: Establish basic TPM policies and goals

  • Analyze existing conditions
  • Set goals
  • Predict results

 

Step 5: Preparation and Formulation of a master plan

  • A master plan lays out your goals, what you will do to achieve them and when you will achieve them
  • Detailed plans for each pillar have to be prepared 


 

Step 6: TPM kick-off

  • The main kick-off to TPM should take the form of a formal presentation with all the  employees attending
  • This opportunity can be used to gain the full support of the employees
  • Invite external customers, affiliated and subcontracting companies


 

Step 7: Develop an equipment management program

  • The tools of Total Quality Management and Continuous Improvement are applied to the management and improvement of equipment
  • Form project teams
  • Select model equipment
    - identify equipment problems
    - analyze equipment problems
    - develop solutions and proposals for improvement
  • Typical membership of a team
    - five to seven operators
    - a maintenance person
    - a technical expert
  • Tools
    - Pareto
    - Cause & effect
    - Root cause
    - Methods Analysis


 

Step 8: Develop a planned maintenance program

  • Set up plans and schedules to carry out work on equipment before it breaks down, in order to extend the life of the equipment
  • Include periodic and predictive maintenance
  • Include management of spare parts and tools


 

Step 9: Develop an autonomous maintenance program

  • A handing-over of maintenance tasks from specialized maintenance personnel to production operators
  • Tasks to hand over
    - cleaning
    - lubricating
    - inspecting
    - set-up and adjustment

 

Step 10: Increase skills of production and maintenance personnel

  • The training sessions must be planned shortly after the kick-off presentation
  • 2 major components
    - soft skills training
    - technical training
  • Train leaders together
  • Have leaders share information with group members

 

Step 11: Develop early equipment management program

  • The principle of designing for maintenance prevention can be applied to new products, and to new and existing machines
  • New products must be designed so that they can be easily produced on new or existing machines
  • New machines must be designed for easier operations, changeover and maintenance
  • Existing machines:
    - analyze historical records for
         - trends of types of failures
         - frequency of component failures
         - root causes of failures
    - determine how to eliminate the problem and reduce maintenance through an equipment  design change or by changing the process

 

Step 12: Perfect TPM implementation and raise TPM levels

  • Evaluate for the PM Award: The Japanese Institute for Productive Maintenance runs the annual PM Excellence Award. They provide a checklist for companies applying for the award
  • Set higher goals

More information about TPM - Total Productive Maintenance - is available at http://www.ManagementGuides.com

 

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    • profile image

      Johnd837 2 years ago

      I like this post, enjoyed this one regards for posting. He removes the greatest ornament of friendship, who takes away from it respect. by Cicero. fgbekgffdeeb

    • profile image

      TPM COACH 5 years ago

      Is great this.

      Now in tpm have 7 steps like that fiat group

      best regards

    • profile image

      Roger  7 years ago

      Very interesting outline for implementation of this process.

    • seyiari profile image

      seyiari 8 years ago

      I THINK THIS IS GREAT.

    • profile image

      pradeep 8 years ago

      can u eloborate why external customers are invited.what will be their contribution in TPM.(Step-6)

    • profile image

      J. Ombogo 8 years ago

      Involving operators for machine condition monitoring is very important and this assist in eliminating any impending failure before failure occurs.

      Cheers

    • profile image

      joao assis 8 years ago

      Great job. I`m waiting for Lean steps implementation.

      Thanks