As the name suggests, the main eight pillars of TPM are the framework, which supports the TPM activities in any organization. Before we talk about these eight pillars of TPM, It is important to also look at the foundation blocks of TPM.
Foundation Blocks of TPM
The foundation blocks include:
- Total employee participation
- P, Q, C, D, S, M, and E
TPM is more of a tool and a culture or bringing in organizational change and to improve employee involvement and organization profitability. There is a proven 12 Steps Methodology to be used for TPM implementation. Unlike Six Sigma, TPM is a logical and a systematic improvement methodology that can bring phenomenal organizational change. Choose between TPM and Six Sigma methodology to understand which is the right methodology for you.
As mentioned, TPM is centered around employee involvement and making them as change agents in the organization. Also, 5S, which are the 5 Japanese words all starting with S (Seiri, Seiton, Seiso, Seiketsu, and Shitsuke) is another foundation block for success TPM implementation. In fact, I will say it is a prerequisite for TPM implementation. The third foundation block is P, Q, C, D, S, M, and E. These seven alphabets represents the seven cornerstones of any organization.
- P – Productivity
- Q – Quality
- C – Cost
- D – Delivery
- S – Safety
- M – Morale
- E – Environment
Now that you know about these cornerstones, you will agree that an organization cannot be successful without them.
For any strong building that can stand any odds, the foundation is the most important step. If the foundation is strong then only we can have strong pillars on which the roof can rest.
After creating the foundation, it is now time to understand the eight pillars of TPM.
The Eight Pillars of TPM
The conventional eight pillars of TPM are:
- Kobetsu Kaizen – Focused Improvement
- Jishu Hozen – Autonomous Maintenance
- Kaikaku Hozen – Planned Maintenance
- Hinshitsu Hozen – Quality Maintenance
- Education and Training
- Safety Health and Environment
- Development Management
- Office TPM
The name of the pillars typed in italics are the Japanese version. Adjacent to it are the English names of these pillars. Sometimes their names become so difficult to remember that people spend more time in remembering these Japenese words. The same applies to the documentation required for TPM activities. In my post Is Documentation A Cause Of Concern For TPM Implementation?, I have addressed some such concerns.
The eight pillars of TPM focuses on proactive and preventative techniques for improving equipment reliability. Once you start advancing in your TPM journey, we can add more pillars of TPM.
Kobetsu Kaizen – Focused Improvement
Identifies the critical areas of the organization that needs improvements from Key indicators of P, Q, C, D, S, M & E using tools like the Loss – Cost Matrix (LCM). The losses in the organization are quantified under 16 categories, and small groups of employees work together proactively to achieve regular, incremental improvements in organizational performance.
- Reduction in organizational losses makes the organization more profitable
- Combines the collective talents of a company to create an engine for continuous improvement.
- Recurring problems are identified and resolved by cross-functional teams.
Jishu Hozen – Autonomous Maintenance
Empowers the operators to perform maintenance of equipment. The operators take on the routine maintenance including cleaning, lubrication, and inspection and tightening (CLIT) of parts. Jishu Hozen apparently looks very appealing to implement but there a lot of challenges in implementing it. In my post Live-In Culture – A Challenge For Implementing Autonomous Maintenance?, I have addressed some such challenges.
- Brings in a culture of “I Operate I Maintain.”
- Increased “Operators Ownership” of the equipment.
- Increases operators’ knowledge of their equipment.
- Ensures equipment is well-cleaned and lubricated.
- Creates time for the maintenance professionals to perform highly skilled jobs.
- Identifies new issues before they become failures.
Keikaku Hozen – Planned Maintenance
Carry out scheduled maintenance tasks based on predicted, preventive, time and condition.
- Reduced MTTR and improved MTBT
- Significantly reduces instances of unplanned stop time.
- Reduced inventory through spare parts standardization and enhanced life of spare parts.
- Effective utilization of maintenance skills of the maintenance team.
- Reduction in Maintenance cost.
Hinshitsu Hozen – Quality Maintenance
Using various tools like the figure of 8 kaizen, carry out RCA (Root Cause Analysis) to eliminate recurring sources of quality defects.
- Reduced number of defects
- Improved customer satisfaction
- Reduced cost of quality
Development Management / Early Equipment Management
- Prepare the product/machine for a vertical takeoff.
It has to two substreams.
- New equipment
- New product
Design and performance issues are considered at the design stage, and corrective actions are taken right at the start.
- Reduced Life Cycle Cost (LCC)
- Desired OEE (Overall Equipment Efficiency) achieved right from the beginning
- Reduced teething problem of the equipment
- Equipment designed as per the process requirements.Minimized rework
- Reduce developmental time for New Product
- Reduced developmental cost
Education and Training
Identify the knowledge gaps and take necessary actions to improve the knowledge and skills of the employees so that the goal of TPM can be achieved.
- Develop knowledge and skills of employees of all the departments in an organization.
- Operators can do better maintenance of the equipment to ensure equipment uptime and quality of product with safety.
- Maintenance professionals become the super-specialists of the equipment
- Office / Administration staff can link their activities with plant performance and improve the quality of work that they do.
- Reduce losses on account of lack of knowledge and skill.
Safety, Health, and Environment
Maintain a safe and healthy working environment.
- Ensures Zero LTA
- Reduces Near Miss Accidents
- Makes the workplace a safer place to work
- Improves health of the employees
- Improves environment by improving Air, Water, Soil quality.
Office TPM / TPM in Administration
Apply TPM techniques to administrative / office functions.
- People can relate their job to organizational profitability rather than working in silos.
- Helps reduce cost
- Reduces downtime on account of support functions
- Reduced Management losses