Deployment of Total Productive Maintenance (TPM) should typically follow a 12 steps methodology. In this article I am going to explain you these Proven 12 Steps Methodology To Be Used For TPM Implementation.
Proven 12 Steps Methodology To Be Used For TPM Implementation
Step 1: Top Management declares its commitment to introducing TPM:
This is the first step in the journey of TPM implementation across the organization. This is the time when the TOP Managements decides that it is going to choose TPM as a methodology for improving the organizational and people performance. The same is communicated through the board meetings, departmental meetings, internal communication and all the possible sources of communication.
Step 2: A publicity campaign is mounted, and TPM orientation session are held:
It is believed that if a change has to happen, it has to begin from the TOP. That’s how TPM deployment also happens. The senior management are the first ones to be oriented and trained on the concepts of TPM. They attend workshops / seminars / trainings to understand the purpose and the deployment methodologies.
Step 3: The site’s basic TPM policy and targets are set:
Now that the senior management is trained, they can envision, what can be derived using TPM as an improvement methodology for the organization and how TPM can be used in the current organizational scenario to address the pain areas / concerns. Based on their understanding, they frame the site’s basic TPM policy, baseline (benchmark) their processes and targets are set to be achieved.
Step 4: A TPM promotion organization is established, and management-led pilot models are commenced:
This is the fourth step in the TPM deployment methodology. To properly deploy TPM culture, a TPM promotion office is set up, Steering Committee is put in place, and Pillar Sub-Committees are formulated and activated.
Step 5: The TPM Master Plan is prepared:
Now that the basic preparation is done, a 3 years master plan is formulated which covers how, what and various pillar activities will be carried out. This TPM Master-plan is like preparing a Master-plan for a city with all the details. This preparation of Master-plan is a very vital step as all the difficulties that the organization can think of has to be considered, so that the Master-plan is practical and can be implemented. At the same time, this plan should not be a lazy plan and all the eight pillar activities have to be considered while preparing this plan.
Step 6: The TPM program is officially kicked off:
This is the time to go live in your TPM journey. This is a visible commitment that the organization demonstrates to its customers, suppliers and other stakeholders. But there are a few check points before the kick off can happen.
Step 7: A system for maximizing production effectiveness is developed, by introducing the following eight pillars of TPM
Now is the time to start implementing TPM activities using the eight pillar approach. In the first phase Kobetsu Kaizen, Jishu Hozen, Keikaku-Hozen and Education and Training has to be initiated.
Step 8: Implementation of Early Management Pillar:
Implementation of early management also known as initial flow control has to be implemented across the organisation. This has to be done both for new product as well as new equipment.
Step 9: Implementation of Hinshitsu-Hozen (Quality Maintenance) Pillar:
Hinshitsu-Hozen also known as quality maintenance has to be implemented across the organisation. The objective of this pillar is to understand and reduce quality defects in the organisation.
Step 10: Implementation of TPM in Administration and Support Departments:
TPM overall improvement in the organisation. A vital step in this regard is to include the administrative and the support function. In the organisation lot many losses are found in these departments. By implementing this pillar we intend to reduce or eliminate the losses happening in these departments thereby making the organisation more profitable.
Step 11: Implementation of SHE (Safety, Health and Environment) Pillar:
Safety health and environment our prime concern for any organisation. Total productive maintenance lays a special focus in this area. All efforts are taken to improve it.
Step 12: TPM is fully implemented and upgraded
This is the time to reap the benefits of TPM implementation. If you feel that the organisation has been able to achieve substantial results and also your organisation has matured, then you should apply for the TPM Excellence Award.
This is the 12 step methodology followed by all the companies practicing TPM the JIPM way.