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Additional Links and other training resources for TPM

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NEW- July 31, 2022 - PAS 1918:2022

Total productive maintenance (TPM).  Implementing key performance indicators.  Guide​

 

Books that help support TPM activities

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TPM New Implementation Program in Fabrication and Assembly Industries                 – JIPM/Shirose et al.

  • This book 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 book was a key reference for our pillar leaders, and we purchased one copy for each pillar leader (our Pillar Leaders were from different locations).  It covers every pillar in detail for the process industries, such as chemical processing, food processing, baking, blending, and mixing.  (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.

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Monodzukuri Test Learning Textbook Sample                         -- JIPM Japan Institute of Plant Maintenance

This book is a sample of the "Monodzukuri Test Learning Textbook." JIPM created this book 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 five pages from each main chapter in the book, which contains 294 pages.  To order this textbook, click this link Textbook.  The English version is about USD 52 or 5500 yen. 

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Autonomous Maintenance in 7 Steps – Masaji Tajiri and Fumio Gotoh

  • This book is a detailed guide for understanding and deploying the Autonomous Maintenance pillar of TPM.  I loved this manual, and although it is quite thorough and a lot to read, it is worth every second of reading if you want to understand this pillar and how to support it.  It covers the philosophy, psychology, and mechanics of this pillar.

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Support for Shop floor teams

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Autonomous Maintenance for Operators      – Productivity Press

  • 1st Edition published in 1997 in English (119 paperback).  This short book 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 booklet is a small paperback manual, similar to the AM for Operators.  The book is full of illustrations, diagrams, tables, and cartoons.  It is easy to read and is great for short training sessions with the operators.

 

TPM Team Guide                          – Productivity press

  • Another small paperback manual focuses on how to form small teams that can learn to manage themselves.  This booklet is also a good training manual for operators learning to operate as an open and creative team to make improvements.  It mainly focuses on autonomous maintenance worker teams but is also useful for higher-level teams in the "Focused improvement" (F.I.) pillar.  (Notice that the line between AM teams and F.I. teams is blurry.  That is because AM teams are key members of Focused improvement teams over time.

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P-M ANALYSIS: An Advanced Step in TPM Implementation           -- Shirose, Kimura, Kaneda

  • The book was first 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 to meet and work with one of the authors, Kimura-san, to learn about the process of phenomena-mechanism Analysis.   P-M Analysis is one of the best true root-cause problem-solving techniques seen.

 

Autonomous Maintenance Basic Maintenance Skills class for operators

One of the key aspects of TPM is to focus on ensuring that every machine that needs to run is running and producing quality work at its designed maximum speed whenever it needs to be running.  One way to ensure this involves Operators, Maintenance workers, and trainers.  These three pillars, AM, PM, & E&T, work together to train operators to identify machine anomalies easily and quickly.  The  Monodzukuri Textbook (From JIPM) describes the information needed 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 and a practical "hands-on" approach, including exposure to real-life equipment in today's industry.  This manual integrates safety and troubleshooting components within each chapter to encourage diagnostic skill-building.

 

Mechanical Trades Pocket Manual 4th Edition                        – Audel

  • This convenient guide covers the latest industrial equipment and 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 guides the hydraulic and pneumatic systems operations.  It features mathematical content 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 outlined in Chapter 5 of the Monodzukuri Textbook (from JIPM).  This chapter starts on page 198 of the 2016 first edition of the textbook.

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MEP - Government support for your Lean programs

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If you need a local, trusted, and vetted consultant for Lean guidance, check out the MEP.   Contact your local office and invite them for a tour and a discussion 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 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 various services, from innovation strategies to process improvements to green manufacturing.

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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 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 funds.

 

You can find your local MEP office at this link

 

For more information about the National Institute of Standards and Technology – MEP program:

 


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video links

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JIPM TPM Award Overview and Example  27 minutes - Narrated PPT

I presented this 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 the use of TPM throughout the company over the last ten years.   The author 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 can it compare to popular programs in the USA, and what does the company gain from the award process?

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TPM Philosophy and Activity  Part 1  10 min.  38 sec.  (from JIPM Web site)

This video gives an overview of TPM, which is suitable for those who are learning TPM for the first time.  It is directly from the jipmglobal.com.  Note: Part 2 is free, but you must register with JIPM  first to gain access. 

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How to Perform a SWOT Analysis for Goal Setting and Planning  26 minutes - Narrated PPT.

I presented this PowerPoint in February 2021 at the NAPIM Manufacturing Symposium, covering key information about a SWOT analysis (Strengths, Weaknesses, Opportunities, and Threats) used for annual goal setting in a TPM plant.  It is a very powerful but simple tool used for strategic planning.  Developed in the 1960s, it is still valuable today.  This tool is a great way to set your KMI, (Key management indicators), and KPI (Key performance indicators) used in planning for TPM activities.

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TPM – what is it and what is it not…1 min 14 seconds  (Courtesy of Stuart Veitch of OpEx Solutions)  A nice short and sweet pictorial video on what TPM is.

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TPM and Lean 6 min.  57 sec.  (Courtesy of Stuart Veitch of OpEx Solutions)

A short narrated video that helps explain the link between TPM and Lean activities. 

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TPM Pillar Autonomous Maintenance  3 min. 13 sec. - (Courtesy of Stuart Veitch of OpEx Solutions)  A Nice short and sweet narrated video on the activities of the Pillar Autonomous Maintenance.  (One of the 8 TPM Pillars)

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TPM Pillar for Quality Maintenance  2 min.  52 sec.  (Courtesy of Stuart Veitch of OpEx Solutions)  A short video on the 10-step process for The QM Pillar (One of the 8 TPM PIllars)

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Websites and articles for training on lean concepts

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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:

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The #1 goal is to keep the machines running at full speed and make good products whenever they need to run.   Make sure that all departments focus on the #1 goal. 

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See the definition by Seiichi Nakajima (Known as the Father of TPM) below:

​"TPM is a plant improvement methodology that enables continuous and rapid improvement of the manufacturing process through the use of employee involvement, employee empowerment, and closed-loop measurement of results."… "Carried out by all employees through small group activi." es".   

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Gemba Academy

A great service for delivering Lean training created by the "Gemba Academy." They have a video library with over 1500 lessons and also offer an LMS to help organize, verify, and track the training of your employees.  You can sample some of the introductory lessons for free on their website, School-of-lean, but you must subscribe for the full slate of courses; the first lesson in each category is free, about 5 -15 minutes, and is a great executive summary for someone wanting to become familiar with the key concepts.  Some free examples are:   ​
 

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Gemba Academy podcasts

In addition to the training videos, Gemba Academy offers over 350 free audio recordings available online, which anyone can download for free.  These include interviews with companies working with lean and examples of how companies use lean concepts. 

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Mike Rother - author of Toyota Kata

In the Book "Toyota Kata," Mike Rother reveals that many Americans miss the Toyota Production System, which is all about the organization's culture.   Most lean practitioners focus on the lean tools and lose sight of the lean culture.  TPM requires everyone's involvement, but how do we make it happen?  Toyota Kata is the key.  Mike has an excellent website 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 39-minute Toyota Kata course on the basics of Toyota Kata, which summarizes 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.

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