An introduction to the book TPM for Executives and Managers - A Powerful Holistic Methodology for Managing a Manufacturing Operation At Peak Performance. © 2020
I hope to release the book in late 2024
About the author
Joe Cichon is a retired Senior VP of manufacturing from Inx International Ink Co. During his 46-year career at Inx he devoted most of his time at the senior management level in 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.
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 trying to better understand how TPM works, and what types of activities are involved within TPM. Although the book is built around the JIPM TPM awards, keep in mind 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)
Introduction:
The reader can explore a powerful holistic methodology for managing a manufacturing operation at peak performance. I spent the last 16 years of my career 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 award was presented 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.
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 and success depends on proper implementation, training, and support from top management. TPM requires a long-term commitment and a willingness to change the way things have been done in the past.
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.
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.
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.
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 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.
Table of Contents
About the author
Dedication
Preface
Introduction:
1 Executive Summary – Summary of all chapters
Total Productive Maintenance is Totally Effective Management
2 What is TPM?
2.1 History of TPM -
2.2 TPM according to the JIPM
2.3 TPM is not just an enhanced maintenance program
Metrics And Measures Of Progress
3 TPM Metrics
3.1 PQCDSME
3.2 KMI (Management), KPI (Performance, and KAI (Activity) indicators
3.3 OEE
3.3.1 OEE on the constraint process
3.4 Key Activity Indicators are used to track the progress of TPM activities
Communication – Group Communication Across The Silos Of The Factory
4 Display Boards
4.1 Shop Floor Activity Boards
4.2 Plant TPM board
TPM Loss Intelligence To Find The Hidden Losses In Your Factory
5 TPM and Losses
6 TPM Pillars
6.1 Direct Production Pillars
6.2 Other Essential Pillars
7 TPM and Quality Management
8 TPM has a strong focus on keeping equipment running
Psychological Factors Of Factory Management
9 Psychological factors of TPM deployment
9.1 Example of a pillar approach that assures success
9.2 TPM Considers The Impact Of Change And Increases Pride.
Accurate Training References For TPM Deployment
10 JIPM Body of Knowledge for Education on TPM
10.1.1 English TPM reference books available to purchase from JIPM
10.1.2 The BSI Publicly Available Specification from JIPM - PAS 1918:2022
The TPM Award for Excellence
11 The TPM Award Process
11.1 History of the TPM Excellence Awards
11.2 Cost of TPM Award Application
11.3 Application for the TPM Award
11.4 Timeline to achieve the TPM Award from JIPM
11.5 Advantages of Receiving the TPM Award from JIPM
12 The Values of TPM Deployment
13 TPM Award Checklists for The TPM Award from JIPM
13.1 New - Self-checklist released by JIPM in 2023
13.2 Assessment Criteria for All Categories of TPM Award (1 page)
13.2.1 Key Elements for Successful TPM Implementation The first checklist
13.3 Checklist C covers the first three levels of TPM awards (2 pages)
13.3 Checklist B – Special Award for TPM Achievement (2 pages)
13.5 Checklist A – Advanced Special Award for TPM Achievement
13.6 Checklist S – Award for World-Class TPM Achievement
14 Changes to the TPM Award Process Announced by JIPM July 2023
Total In TPM Means Everyone Is Involved At Keeping The Machines Running
15 Essential Elements of The TPM Pillars
15.1 Focused Improvement
15.2 Autonomous Maintenance
15.3 Planned Maintenance
15.4 Quality Maintenance
15.5 Early Management
15.6 Education and Training
15.7 Improvement of the Administrative and Indirect Departments
15.8 Safety, Health, and Environment
Where To Start Deployment In The USA
16 Starting activities to apply for the TPM award
17 Written Training resources, Publications, and websites
18 Glossary
18 Index
19 References