Genre: Business and Economics

Sub category

• • Manufacturing Management

  • Quality Control

  • Industrial Management and Leadership

  • Operational Excellence

  • Total Productive Maintenance (TPM) implementation for leadership

• Format: Non‑fiction, professional/technical business guide

 

​About the author

Joe Cichon is a retired Senior VP of manufacturing from Inx International Ink Co. During his 46-year career at Inx, and he devoted most of his time at the senior management level to quality management and technology-oriented project management roles. Joe has spent his last 16 years helping to support TPM activities throughout the US locations of INX International Ink Co. 

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Preface

This book is intended to guide company executives and managers of manufacturing companies to understand the concepts of TPM (Total Productive Maintenance) as developed and documented by the JIPM (Japan Institute of Plant Maintenance). It may also be helpful for anyone to try to understand better how TPM works and what types of activities are involved within TPM. Although the book is about the JIPM TPM, remember that the JIPM works continuously to evolve TPM to fit the needs of manufacturing companies, so I have included links directly to the JIPM website. You can find the latest updated information on documents, award schedules, requirements, books, and new concepts there.    https://jipmglobal.com/  (English landing page for JIPM)

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For More information on the release of the book contact me at JoeC@makeefficiency.com 

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Introduction:

The reader can explore a powerful holistic methodology for managing a manufacturing operation at peak performance. I spent the last 16 years working with consultants and mentors from Japan to understand TPM and initiate TPM activities at each of the company's major manufacturing locations in all departments, from order entry through service and delivery. In 2010, we confirmed our understanding with the application for the JIPM TPM Excellence Award. After a rigorous auditing process by the JIPM, the facility in Kansas received the award for "TPM Excellence Category A." The JIPM presented the Award in Kyoto, Japan. TPM has been a key success factor in the company's (Inx International) growth, and advancement in the manufacturing processes at all locations.

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Do not be misled by the word maintenance in "Total Productive Maintenance." TPM is a way to manage all areas, and every system in the factory. It's worth noting that TPM is not a one-size-fits-all approach coach, and success depends on proper implementation, training, and support from top management. TPM requires a long-term commitment and a willingness to change how things have been done in the past.

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The ultimate goal of TPM is to keep all machines running at full speed, producing 100% quality products whenever the machines are needed to run. This goal is achieved by finding, and eliminating losses, and reaching a level of zero breakdowns, and zero defects.

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This book is focused on TPM's concepts, philosophy, history, and psychology according to the JIPM. It covers key information to help executives and managers understand  and support TPM activities within an organization. This includes team structures, organizational alignment, physical management, coordinated activities, and cost/benefit analysis tools.

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This guide will not delve too deep into the technical details of TPM. The knowledge body of TPM has been well-defined and refined by the JIPM and JMA (Japan Management Association) over the last 50 years. There is a lot of literature and courses on TPM in the USA, but not all of them are accurate or complete. The final chapter of this book includes a resource listing that will ensure that the reader is aware of the best information to support the plant and the employees on their road to a factory with zero breakdowns, 100% quality, and zero losses.

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The focus is on an overview of the key concepts involved with TPM deployment at a single location or for an entire organization. I will also include some information on the TPM award process. If you are an executive or manager, this will give you information to help you decide if TPM is right for your location(s). This information, will help managers and Executives to successfully deploy TPM which can help reduce the need for heavy capital investment by focusing on extending the life cycle of equipment and continuous improvement in the systems within the factory.

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Table of Contents

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About the author

Dedication

Acknowledgments;

Preface

Introduction:

1      Executive Summary – Summary of all chapters

2      What is TPM?

3      TPM Metrics

4      Display Boards

5      TPM and Losses

6      TPM Pillars

7      TPM and Quality Management

8      TPM Keeps the equipment running when needed.

9      Psychological factors of TPM deployment

10    JIPM Body of Knowledge for Education on TPM

11    The TPM Award Process

12    The Values of TPM Deployment

13    TPM Award Checklists for The TPM Award from JIPM

14    Changes to the TPM Award Process Announced in 2023

15    Essential Elements of The TPM Pillars

16    TPM Pillar Activities

17    Deploying TPM Activities in 12 Steps

18    Bibliography

19    Index

20    References