Additional Links and other training resources for TPM
NEW- July 31, 2022 - PAS 1918:2022 Total productive maintenance (TPM). Implementing key performance indicators. Guide
JIPM announced a new Publicly Available Standard (PAS1918:2022) from the BSI in July of this year.
I am glad to see that they have done this, and I think it is a good move by JIPM to continue to promote knowledge of TPM throughout the world. You can find the table of contents and an introduction at this link. It is a 30 page document covering the bare bones basic principles of TPM,JIPM in a pretty easy-to-read to read format. The PAS documents are similar to ISO standards, however, they are produced on a fast track to help promote understanding. For more information read my overview under more. .
Books that help support TPM activities
TPM New Implementation Program in Fabrication and Assembly Industries – JIPM/Shirose et al.
This is a key reference produced by the JIPM to help solidify the knowledge of TPM for the discrete manufacturing industry. It is a sister publication to the later publication: “TPM in the Process Industries”.
TPM in the Process Industries -- Suzuki et al.
This was a key reference for our pillar leaders, and we purchased one copy for each pillar leader (our PL were from different locations). It covers every pillar in detail, and is specifically written for the process industries; such as chemical processing, food processing, baking, blending, mixing etc. (We make batches of Ink so it was perfect for our application.) For discrete manufacturing you should see the book “TPM Total Productive Maintenance -New Implementation Program in Fabrication and Assembly Industries” by Shirose et al.
This is a sample of the contents from the “Monodzukuri Test Learning Textbook”. This book was created by JIPM to help teach, and test the understanding of the key concepts of TPM. It covers all the TPM Pillars of activity and the key tools used within TPM. Note that this is just a sample and only shows about 5 pages from each main chapter in the book which contains a total of 294 pages. To order this textbook click this link Textbook. The English version is about $52 USD or 5500 yen.
Autonomous Maintenance in 7 Steps – Masaji Tajiri and Fumio Gotoh
This is the detailed guide for understanding and deployment of the Autonomous Maintenance pillar of TPM. I personally loved this manual and although it is quite detailed and a lot to read, it is worth every second of time to read if you really want to understand this pillar and how to support it. It covers the philosophy and the psychology as well as the mechanics of this pillar.
Support for Shop floor teams
Autonomous Maintenance for Operators – Productivity Press
1st Edition published in 1997 in English (119 paperback). This is a great reference for Shop leaders and operators covering most of the basic principles of the AM Pillar of TPM. 50% of the text is in illustrations, diagrams and cartoons.
5S for Operators -- Productivity Press
This is a small paperback manual, similar to the AM for Operators. The book is full of illustrations, diagrams, tables, or cartoons. This is easy to read, and can be used in short training sessions with the operators.
TPM Team Guide – Productivity press
Another small paperback manual that focuses on how small teams can be formed and learn to manage themselves. This is also a good training manual for operators that are learning to operate as an open and creative team to make improvements. This is mainly focused on Autonomous Maintenance worker teams, but is also useful for higher level teams for the “Focused improvement” (FI) pillar. (Notice that the line between AM teams and FI teams is blurry. That is because; overtime AM teams are key members of Focused improvement teams.
P-M ANALYSIS: An Advanced Step in TPM Implementation -- Shirose, Kimura, Kaneda
Published in 1995 in English ~185 pages paperback. This book covers a very powerful and sophisticated approach to solving chronic problems. I had the opportunity of meeting and working with one of the authors; Kimura san, to learn about this Phenomena-Mechanism Analysis process. P-M Analysis is one of the best true root cause problem solving techniques, I have ever seen.
Autonomous Maintenance Basic Maintenance Skills class for operators
One of the key aspects of TPM is to place a strong focus on making sure that every machine that needs to run is running and producing quality work at it’s designed maximum speed, whenever it needs to be running. One area to assure this involves Operators, Maintenance workers and trainers. These 3 pillars AM, PM, & E&T, work together to provide training to operators so that they can identify machine anomalies easily and quickly. The Monodzukuri Text book (From JIPM) describes the information that needs to be covered in this training in chapter 5. The following four manuals were all used to support this training. We purchased enough of these manuals to provide one to every operator during and after their training.
Industrial Mechanics and Maintenance – Chastain
This modern book presents a solid foundation in basic theory coupled with a practical “hands-on” approach that includes exposure to real-life equipment used in the industry today. This manual integrates safety and troubleshooting components within each chapter to encourage diagnostic skill-building.
This convenient guide covers the latest industrial equipment as well as all the tools and machines prevalent in older plants, even those from the early 1970s and before.
Hydraulics and Pneumatics – Parr
Hydraulics and Pneumatics: A Technician's and Engineer's Guide serves as a guide to the hydraulic and pneumatic systems operations. It features mathematical content that has been presented in a style understandable even to beginners and non-experts.
Electrical Course for Apprentices & Journeymen, 4th Edition -- Audel
It contains everything you need to know about electrical theory and applications, clearly defined and logically organized, with illustrations for clarity and review questions at the end of each chapter to help you test your knowledge.
Also see the operator training material that is outlined very nicely in chapter 5 of the Monodzukuri Text book (from JIPM). This chapter starts on page 198 in the 2016 first edition
MEP - Government support for your Lean programs
If you need a local, trusted and vetted consultant for Lean guidance, check out the MEP. Contact you local office and invite them in for a tour and a discussion and to learn what might be available. They will not charge you for the visit. “The MEP National Network comprises the National Institute of Standards and Technology’s Manufacturing Extension Partnership (NIST MEP). There are 51 MEP Centers located in all 50 states and Puerto Rico. The Manufacturing Extension Partnership is a federally funded program to help small to medium sized businesses to plan, execute and maintain a strategy and training for a strong manufacturing business. The MEP works with small and mid-sized U.S. manufacturers to help them create and retain jobs, increase profits, and save time and money. The nationwide network provides a variety of services, from innovation strategies to process improvements to green manufacturing.
Supported by the Federal and State Government
MEP is a public-private partnership, designed from inception as a cost-share program. Federal appropriations pay one-half, with the balance for each Center funded by state / local governments and/or private entities, plus client fees. This cost-share model contributes to MEP's success. A GAO study found that because client fees give manufacturers a higher stake in the outcome of services, the positive impact on their businesses is greater. Meanwhile, public funding allows smaller manufacturers to afford services. NIST MEP uses 2 CFR 200 to monitor and govern the recipients' use of federal fund.
You can find your local MEP office at this link
For more information about the National Institute of Standards and Technology – MEP program:
https://www.nist.gov/mep/about-nist-mep - How it works
https://www.nist.gov/mep - Detailed information, case studies, news updates, and testimonials.
This was Presented in October 2020 at the NAPIM Technical Conference. In 2010 the INX Manufacturing facility in Edwardsville, Kansas applied for the JIPM Award for TPM Excellence. The facility was certified in 2010. INX has continued to expand on the use of TPM throughout the company over the last 10 years. The speaker summarizes the key points of TPM as defined by the Japan Institute of Plant Maintenance. In addition this presentation includes the following key points of TPM: what is it?, How it compares to popular programs in the USA, and what can be gained from the Award process.
TPM Philosophy and Activity Part 1 10 min. 38 sec. (from JIPM Web site)
This video gives an overview of the TPM, which is suitable for those who are learning TPM for the first time. This is directly from the jipmglobal.com . Note: Part 2 is available for free as well, but you must register with JIPM for access.
How to Perform a SWOT Analysis for Goal Setting and Planning 26 minutes - Narrated PPT
This was Presented in Feb 2021 at the NAPIM Manufacturing Symposium, this presentation covers key information about a SWOT analysis (Strengths, Weaknesses, Opportunities and Threats) which can be used for annual goal setting in a TPM plant. It is a very powerful but simple tool used for strategic planning. Developed in the 1960's it is still valuable today.
TPM Pillar Autonomous Maintenance 3 min. 13 sec. - (Courtesy of Stuart Vietch of OpEx Solutions) A Nice short and sweet narrated video on the activities of the Pillar Autonomous Maintenance. (One of the 8 TPM Pillars)
Web sites and articles for training on lean concepts
Much of the training and consultants in the USA do a great job of teaching many of the tools and methods of lean that are the same tools of TPM and TPS. Although these tools and methods can be helpful to TPM deployment, it is important to remember that the underlying principles of TPM need to focus on the following key achievements:
The #1 goal is to keep the machines running at full speed all the time and making good product whenever they need to run. Make sure that all departments are focused on the #1 goal. See the definition by Seiichi Nakajima (Known as the Father of TPM) below:
“TPM is a plant improvement methodology which enables continuous and rapid improvement of the manufacturing process through use of employee involvement, employee empowerment and closed-loop measurement of results.” … “Carried out by all employees through small group activities”.
A great service for delivering Lean training has been created by the "Gemba Academy" They have a video library with over 1500 lessons, and also offer a LMS to help organize, verify, and track the training of your employees. You can sample some of the introductory lessons for free on their web site: School-of-lean, but you will have to subscribe for the full slate of courses. Actually, the first lesson in each category is free, and about 5 -15 minutes and is a great executive summary for someone wanting to become familiar with the key concepts. Some free examples are:
In addition to the training video's, Gemba Academy also offers over 350 free audio recordings that are available online, or can be downloaded free as well, if you want to download to a thumb drive, and learn about a new topic on your way to or from work. These include interviews with companies working with lean, and examples of how companies use the lean concepts.
In the Book "Toyota Kata", Mike Rother reveals the key that many Americans miss in the Toyota Production System, which is all about the organization's Culture. Most lean practitioners, focus on the lean tools; and lose site of the lean culture. TPM requires the involvement of Everyone, but how do we make it happen? Toyota Kata is the key. Mike has an excellent web site with dozens of wonderful lectures on the topic. If you want t learn a little about Kata, here is a 10 minute video Toyota Kata by Mike Rother. If you want to learn a little more here is a Toyota Kata 39 minute course on the basics of Toyota Kata which really does a good job to summarize the concepts behind the thinking process that Japan has developed and infused into TPM. This mindset is very critical to the entire deployment of Lean or TPM.