The Critical Pillar of Lean
Equipment Effectiveness known to many as Total Productive Maintenance or TPM is a well-defined and time-tested concept for maintaining the critical infrastructure of plants or facilities and the equipment within it. We sometimes refer to TPM as the science of machinery health!!
TPM focuses on achieving one aspect of a true quality system that assures equipment, processes, and employees add business value to the organization. In doing so, TPM focuses on achieving the following outcomes:
-No Breakdowns (Capacity Consistency)
-No Small Stops or Slow Running Equipment (Capability Assurance)
-No Defects (Zero Defect Thinking)
-No Accidents (Safety First Thinking)
Learning these techniques that generate value to the business takes time. Since TPM is a method to achieve maximum equipment effectiveness through employee involvement, we at Makoto Flow Ltd. have devised 4 Key Approaches to learning the application of these practices.
1) TPM for Executives Masters Class – 1 Day. In the struggle to stay ahead of the competition, executives around the world are now racing to build flexibility, rapid-response capabilities, re-designing their business processes, re-aligning their structures & leveraging technology with innovation & integrated solutions. TPM is a critical component to that success.
2) TPM Practitioners Workshop – 3 Days. This is a fundamental first step in TPM. Designed to place focus on getting the management, maintenance personnel and equipment users all working together to prevent equipment problems and reduce expenditures.
3) TPM Focused Engagements – 2-3 Months. When adopting TPM practices, its important to experience it first hand. This practical and specific machine type engagement is designed to take the “practitioner” through the initial four (4) pillars of TPM by demonstrating specific actions to improve equipment effectiveness.
4) TPM Advanced Engagements – 6-12 Months. Gain a thorough understanding of the TPM Management System, with all eight (8) pillars and their deliverables. Once these practices are engrained into your daily way of working, the business can ensure total process reliability.
If you want a more comprehensive overview of our TPM opportunities, please reach out to us at [email protected] and we will surely forward that to you via email. As always, I welcome your thoughts about what we've posted above.
Until next time, we truly do wish all of you nothing but great success as you continue down your lean journey! Please remember, "Lean takes practice, not just understanding!"
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6 年TPM is not a "lean" tool. It is a fully fledged company improvement package that should be applied to every department and can take years to implement. Yes, it works well WITH lean but unlike lean, TPM proper needs to have a skilled set of employees using it - coming from an equipment background, I know that equipment maintenance can present a serious risk to safety and must be treated properly. I learned (and applied) TPM before being taught lean and it included its own "version" of SMED, 5S, OEE, problem solving and KPI's. TPM is a great methodology. It will dramatically improve equipment performance, product quality - and profitability. Even I paired it with lean back in 2000 to make it even better, but we must be careful when applying it - and its other pillar "Autonomous Maintenance" which (initially) uses operators to carry out minor, simple maintenance tasks. When teaching operators to carry out maintenance task, safety is a huge consideration as an accident can derail the whole implementation. Yes, we can apply TPM in parallel with lean but it is not a "lean" tool. And yes, the sooner you start learning about it, the better your productivity will become. Steve
Tenured and Semi-Retired Quality Professional consulting in Organizational & Process Excellence
6 年TPM coupled with OEE are the frequently forgotten Lean tools. And they have the best ROI when implemented properly!
Lean Sustainable Systems, Author, Speaker, Blockchain strategist and advocate, coach, consultant and mentor.
6 年Totally agree that without good TPM we cannot have true Continuous Flow Production or JIT Production. TPM is a foundation of Lean production.
Continuous Improvement coaching for all industries. Lean Manufacturing. Lean Six Sigma. Prince2 project management
6 年Thanks for sharing this DJ, once the assumed constraint of “not been able to stop assets” is recognised there is such a massive benefit in a robust TPM system