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How can you sustain TPM implementation benefits in Manufacturing?

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TPM, or Total Productive Maintenance, is a proactive approach to optimize the performance and reliability of your manufacturing equipment. It involves the participation of all employees, from operators to managers, in maintaining and improving the machines they use. By implementing TPM, you can reduce downtime, defects, costs, and accidents, and increase productivity, quality, and customer satisfaction. But how can you sustain the benefits of TPM after the initial implementation phase? Here are some tips to help you keep your TPM program alive and effective.

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Santhosh KV ( AMIE .Chartered Engineer India )

Vice President Operations & TPM Facilitation

1 Establish a TPM culture

One of the key factors for sustaining TPM benefits is to create a culture of continuous improvement and ownership among your employees. This means that everyone should understand the goals and benefits of TPM, and be committed to follow the standards and procedures for maintaining and operating the equipment. You can foster a TPM culture by providing regular training, recognition, feedback, and communication. You should also encourage cross-functional teamwork and problem-solving, and involve employees in setting and reviewing TPM objectives and indicators.

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Fernando Orio

Ingeniero Especialista en Procesos Industriales
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Como toda herramienta de cambio cultural en las organizaciones, el TPM debe apuntar en sus aplicaciones que cada operario, técnico, supervisor realicen las acciones con un convencimiento de que sus puesto de trabajo son justamente eso "sus puestos de trabajo" y son ellos los principales encargados de cuidar y hacer cumplir que cada "M" del procesos este en las condiciones optimas conforme fueron concebidas, el TPM nos hace pensar que cada puesto de trabajo es nuestro como si fuera algo de nuestra misma casa, las fabricas son nuestras segundas casas y deben tener el mismo concepto de cuidado y mantenimiento.

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2 Monitor and measure TPM results

Another important aspect of sustaining TPM benefits is to monitor and measure the performance and condition of your equipment, and the impact of TPM activities on your key performance indicators (KPIs). You should use reliable and relevant data to track and analyze the effectiveness of your TPM program, and identify the gaps and opportunities for improvement. You should also use visual management tools, such as charts, boards, and dashboards, to display and share the TPM results with your employees and stakeholders. This way, you can motivate and engage your workforce, and align your TPM efforts with your strategic goals.

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3 Implement kaizen and PDCA cycles

A third tip to sustain TPM benefits is to implement kaizen and PDCA cycles to continuously improve your equipment and processes. Kaizen is a Japanese term that means "change for the better", and it refers to the practice of making small and incremental improvements on a regular basis. PDCA is an acronym for Plan-Do-Check-Act, and it is a four-step method for implementing and evaluating changes. By applying kaizen and PDCA cycles, you can systematically identify and eliminate the root causes of equipment failures, defects, and waste, and ensure that the improvements are sustained and standardized.

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Santhosh KV ( AMIE .Chartered Engineer India )

Vice President Operations & TPM Facilitation
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Use TPM as a business tool. Use strategy of deepening and widening TPM to all aspects of business. Challenge all un attended areas in business. Use extensively for new product Development activities

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Luis Fernando Gonzalez Ramirez

Lean Six Sigma Black Belt
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In TPM, there is a powerful tool for making small improvements while standardizing knowledge generated through experience. This tool is the One-Point Lesson (OPL), which enables anyone to generate a solution to a problem based on their experience and can train all other employees who need it using the OPL as training material.

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4 Review and audit TPM activities

A fourth suggestion to sustain TPM benefits is to review and audit your TPM activities periodically to ensure that they are aligned with your TPM policy and plan, and that they are executed correctly and consistently. You should conduct internal and external audits to verify the compliance and effectiveness of your TPM system, and to identify the strengths and weaknesses of your TPM practices. You should also review your TPM results and feedback with your employees and stakeholders, and celebrate your achievements and learn from your failures.

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Luis Fernando Gonzalez Ramirez

Lean Six Sigma Black Belt
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Every system tends to decline if not monitored and energized to shape it. Audits serve that function in the TPM system, preventing the natural decline of the system and metrics while providing a measurable indicator of our implementation level. In TPM, the highest level of audit is conducted by JIPM (Japan Institute of Plant Maintenance).

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5 Benchmark and learn from best practices

A fifth recommendation to sustain TPM benefits is to benchmark and learn from the best practices of other organizations that have successfully implemented and maintained TPM. You should research and visit other companies that have achieved excellence in TPM, and compare your performance and processes with theirs. You should also seek feedback and advice from TPM experts and consultants, and join TPM networks and forums to exchange knowledge and experiences. By benchmarking and learning from best practices, you can gain new insights and ideas to improve your TPM program and overcome your challenges.

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Luis Fernando Gonzalez Ramirez

Lean Six Sigma Black Belt
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Another good practice that I can share, derived from Toyota, is to benchmark with suppliers from the same customer, even if they are not in the same industry. Taking Toyota as an example, they gather seat, brake, engine suppliers, etc., and conduct improvement workshops focused on obtaining the best practices from each. Even if at first glance, two industries may seem unrelated, there is always something to learn.

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6 Innovate and adapt to changes

A sixth and final tip to sustain TPM benefits is to innovate and adapt to the changes in your internal and external environment. You should not be complacent or satisfied with your current TPM performance, but always look for ways to enhance your equipment and processes. You should also be aware of the changes in your customer needs, market trends, technology, and regulations, and adjust your TPM strategy and tactics accordingly. By innovating and adapting to changes, you can ensure that your TPM program remains relevant and competitive in the long run.

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7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Brian A. Price, EIT

Continuous Improvement Engineer | Trainer | Problem Solver | TPM Implementer | Waste Reducer | People Leader |
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One of the most important things I have seen in long term sustainability and success of TPM is making sure the operators are involved where they can be. I have seen both sides where operators feel management is driving TPM and so they don't have to do anything and the progress made is short lived. However, when an operator from the floor owns their area and is driving TPM such as full problem solving or CIL and Centerline implementation and improvement, progress is improved and accelerated. It is amazing seeing associates take the tools and drive the TPM vehicle themselves. They then see the fruits of their labors and continue to encourage their peers to continue the worthwhile efforts.

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How can you sustain TPM implementation benefits in Manufacturing?

1

2

3

4

5

6

7

1 Establish a TPM culture

2 Monitor and measure TPM results

3 Implement kaizen and PDCA cycles

4 Review and audit TPM activities

5 Benchmark and learn from best practices

6 Innovate and adapt to changes

7 Here’s what else to consider

Manufacturing

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How can you sustain TPM implementation benefits in Manufacturing?

1

2

3

4

5

6

7

1 Establish a TPM culture

2 Monitor and measure TPM results

3 Implement kaizen and PDCA cycles

4 Review and audit TPM activities

5 Benchmark and learn from best practices

6 Innovate and adapt to changes

7 Here’s what else to consider

Manufacturing

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