Synthesis and overview of the TPM Method

As a Lean black belt and cost reduction expert, I wrote this article in 2009 on KNOL, then Wordpress, and now I decided to share it on Linkedin. The main driver is the understanding that reducing waste through targeted measures and associated actions will contribute to a healthier planet.

The measurable return on investment in terms of cost savings, improved quality, and shorter lead times make it a mutually beneficial proposition for both the company and the environment.

TPM Method

Synthesis and overview

Synthesis of the TPM method : improve the production output, productivity, quality and the lead times. Eliminate all kind of waste. The TPM Method is used in Lean manufacturing / Just in time (JIT) / Toyota Production System (TPS) / …

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What is the TPM ?

TPM = Total productive Maintenance, is a Japanese method designed to maximize the production output (and then the Overall Equipment Effectiveness – OEE) thanks to the involvement of the employees and the wastes eradication.

This method is built on several key aspects: autonomous maintenance, preventive maintenance, mistake-proofing.

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Origins of the TPM

The origins come from a mix of preventive maintenance from USA and the staff involvement idea from Japan. Thus, in 1971, Nippondenso (that was a part of Toyota group in 1949) was the first company to implement the TPM method in creating the autonomous maintenance, and won the first TPM award from the JIPM (Japan Institute of Plant Maintenance) .

Aims of the TPM

• To reach the maximum equipment output (find and eliminate all waste = see the OEE KPI) and then hold emergency and unscheduled maintenance to a minimum: target is ZERO breakdowns.
• To have a longer life cycle for production equipment: it reduces the production costs.
• To increase employees’ morale and job satisfaction.
• To reduce the accidents: target is ZERO accident.
• To eliminate product defects: target is ZERO defects.

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ROI

A TPM project can bring a huge payback in many ways: productivity, lead times, quality, and security.

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Implement the TPM

• Read the OEE article, apply it on the equipments
• Read the 5S article
• Read the SMED article
• Transfer the set up, cleaning and machine inspection from maintenance team to the employees (involve them) : it is called automaintenance
• Do a mistake proofing (also called poka yoke) brainstorming and implement the solutions
• Implement a scheduled maintenance
• Implement the 5M method