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, he devoted most of his time to quality management and technology-oriented project management roles at the senior management level. Joe has spent the last 16 years supporting TPM activities across INX International Ink Co.'s US locations. 

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Preface

This is the book we all wish we had had when we decided to pursue the JIPM TPM Excellence award. It is worth its weight in gold.

 

With many of our startup and deployment team members, we learned so much (the hard way) about the process and the JIPM framework over the years.  This book is intended to guide company executives and manufacturing managers in understanding the concepts of TPM (Total Productive Maintenance) as developed and documented by the JIPM (Japan Institute of Plant Maintenance). It also helps anyone better understand how TPM works and what types of activities are involved in TPM. Remember that the JIPM continually evolves to meet 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 or if you wish to apply for the TPM Award, contact me at JoeC@makeefficiency.com. I would be glad to respond or even set up a short phone call to discuss any questions you may have. 

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Introduction:

The reader can explore a powerful, holistic methodology for managing a manufacturing operation at peak performance. I spent over 20 years working with consultants and mentors from Japan to understand TPM and to initiate TPM activities at each of the company's major manufacturing locations across 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; 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 they are needed. 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 focuses 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 to ensure the reader is aware of the best information to support the plant and its 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 provide information to help you decide whether 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

​About the author
Dedication
Acknowledgments;
Preface
Introduction:
1    Executive Summary – Summary of all chapters
2    What is TPM?
2.1    How was TPM Developed, and What is the Link to American Quality Concepts?
2.2    TPM according to the JIPM
2.3    TPM is not just an enhanced maintenance program

3    TPM Metrics
3.1    PQCDSME
3.2    Key Indicators KMI, KPI, and KAI
3.3    OEE
3.3.1    OEE on the constraint process

4    Display Boards
4.1    Shop Floor Activity Boards
4.2    Plant TPM board

5    TPM and Losses

6    TPM Pillars
6.1    Direct Production Pillars
6.2    Other Essential Pillars

7    TPM and Quality Management

8    TPM keeps the equipment running when needed.

9    Psychological factors of TPM deployment
9.1    Example of a pillar approach that ensures success
9.2    TPM Considers the Impact of Change and Increases Pride.

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

11    The TPM Award Process
11.1    History of the TPM Excellence Awards
11.2    What is the TPM Award, and who issues it?
11.3    Cost of TPM Award Application
11.4    Application for the TPM Award
11.5    Timeline to achieve the TPM Award from JIPM
11.6    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    JIPM Self-checklist released 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)
13.4    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 in 2023
15    Essential Elements of The TPM Pillars
15.1    TPM Pillar Leaders
15.2    TPM Pillars help to break down barriers between work centers.
15.3    Responsibilities for Pillar Leader:
15.4    Responsibilities for Corporate Pillar Leaders
15.5    Responsibilities for Local Pillar Coordinator:
16    TPM Pillar Activities
16.1    Focused Improvement
16.1.1    FI Aim: (Intention or direction)
16.1.2    Purpose: (Why we do it)
16.1.3    FI Benefits:
16.1.4    FI Pillar Goals
16.1.5    FI uses a ten-step process:
16.1.6    Key Points For Focused Improvement
16.1.7    Examples of special Tools used by the Focused Improvement pillar:
16.2    Autonomous Maintenance
16.2.1    Aim:
16.2.2    Purpose:
16.2.3    Benefits:
16.2.4    AM Pillar Goals
16.2.5    The Seven Steps of Autonomous Maintenance
16.2.6    Key Points of AM
16.2.7    Examples of special Tools used
16.3    Planned Maintenance
16.3.1    Aim:
16.3.2    Benefits:
16.3.3    Pillar Steps for Planned Maintenance:
16.4    Quality Maintenance
16.4.1    Aim:
16.4.2    Purpose
16.4.3    Benefits:
16.4.4    QM Pillar Metrics
16.4.5    Quality Management is carried out in 10 steps:
16.4.6    Key points for the QM Pillar
16.4.7    Examples of special Tools used for QM Pillar
16.5    Early Management
16.5.1    Aim:
16.5.2    Purpose:
16.5.3    Benefits:
16.5.4    EM Pillar Metrics
16.5.5    The Early Management Pillar Uses a Reiterative Four-Step Process
16.5.6    Key points for this pillar:
16.5.7    Examples of special Tools used
16.6    Education and Training
16.6.1    Aim:
16.6.2    Purpose:
16.6.3    Benefits:
16.6.4    Education and Training Pillar Metrics
16.6.5    Pillar Steps for Education and Training Pillar:
16.6.6    Key Points for this Pillar
16.7    Improvement of the Administrative and Indirect Departments
16.7.1    Aim:
16.7.2    Purpose:
16.7.3    Benefits:
16.7.4    Admin and Indirect  Pillar Metrics
16.7.5    Pillar Steps:
16.7.6    Key points for this pillar:
16.8    Safety, Health, and Environment
16.8.1    Aim:
16.8.2    Purpose:
16.8.3    Benefits:
16.8.4    Key Points:
16.8.5    Safety, Health, and Environment Pillar Metrics
16.8.6    Pillar Steps:
16.8.7    Examples of special Tools used
16.8.8    Key points for this pillar:
17    Deploying TPM Activities in 12 Steps
17.1    Table 15 Twelve Steps for the TPM Implementation Program
17.2    Where to Begin
17.3    Step Zero—Labor Unions
17.4    Step 1: Top management declaration.
17.5    Step 2: TPM Introduction Education and Campaign
17.5.1    Consultants for TPM Outside of Japan
17.5.2    JIPM Pre-assessment Service for the TPM Excellence Awards
17.6    Step 3: Formation of TPM Promotion Organization and Formal Organizational Model
17.6.1    TPM Promotion Organization
17.6.2    TPM Pillar Leader Team at the Corporate Level
17.6.3    Model Projects for Focused Improvement and Autonomous Maintenance.
17.7    Step 4: Setting Basic Policy and Targets of TPM
17.8    Step 5: Preparation of a Master Plan for Implementing TPM.
17.9    Step 6: TPM Kickoff
17.10    Steps 7 through 11 - Introduction- Executing the Eight Pillars of TPM
17.11    Step 12 Complete Implementation of TPM is Established
18    Bibliography
18.1    PAS 1918:2022 Total productive maintenance (TPM) - Implementing key performance indicators. Guide, JIPM/BSI
18.2    Training Books and Resources from JIPM (web page)
18.2.1    English TPM Glossary, JIPM
18.2.2    TPM New Implementation Program in Fabrication and Assembly Industries, Shirose, JIPM
18.2.3    TPM in the Process Industries, Suzuki et al. JIPM 
18.2.4    Monodzukuri Test Learning Textbook, JIPM
18.2.5    Autonomous Maintenance in 7 Steps, Tajiri, Gotoh
18.2.6    Total Productive Maintenance Training Textbook ─Appendix Total Productive Maintenance for Process Industries, JIPM
18.3    Autonomous Maintenance Basic Maintenance Skills Training for Operators
18.4    MEP - Government support for your Lean programs
19    Index
20    References

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