TPM (Total Productive Maintenance) focuses on identifying losses in the factory.

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“The single biggest problem with communication is the illusion that it has taken place,” George Bernard Shaw.

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Suggestions are an extremely effective way to uncover hidden losses in your factory.  But if they are not 100% reviewed, acknowledged, and acted upon, we are not only losing the great ideas but also killing the goose that laid the golden egg, as the desire to come up with new suggestions diminishes.

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The TPM team structure is designed to give everyone as many opportunities as possible to share their ideas and turn them into improvements that help everyone. 

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Many suggestion systems fail because suggestions are hidden in a box and then disappear. It may be weeks before the employee even knows if his suggestion was seen. Rarely does management take the time to review them regularly, and even more rarely does it engage in a dialogue with the person who submitted them.   Sometimes what appears to be a “bad” suggestion can be the frame around a problem that, with some discussion, can generate a “great” suggestion.

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Creating an effective visual suggestion system

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An important aspect of TPM is the concept of a visual workplace, where anyone can quickly find needed information, and keep track of metrics, and progress.  Suggestions can be most effective when managment supports them, and it is easy for employees to make suggestions and obtain a dialogue with the right people to determine how best to use the suggestions.

 

Following is the description of one system that has been seen to be very effective for encouraging the generation of many suggestions.

 

1. Create a visual system to review every suggestion effectively.

2. Acknowledge every suggestion (good or bad)

3. Use the suggestions to create a dialogue with the person who submitted it.

4. Leave the suggestion on the board and indicate the status by moving it to the next section of the board.

 

Start by asking team members to submit Ideas on a suggestion form.  You can help stimulate ideas by posting a question or problem to focus on.  Start with a bulletin board in various work areas or meeting areas.

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Develop a simple suggestion card, keep empty cards, and a pen near the Suggestion board.

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Use a system that encourages brief, readily displayed ideas that are moved visibly.  Remember the ownership factor. Keep and manage the ideas in their original form and keep them visible in the workplace.  People feel more ownership when suggestions retain their own handwriting and signature. Computer lists are a form of alienation, especially for those who do not work in this medium every day.  If it is in the computer, the idea has become "yours." If it is in my handwriting, it stays "mine."

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Layout for the Suggestion Board

1. TO DO – The ideas are screened and either advanced to an action item or rejected.  If an idea is rejected, it is important to discuss it with the author and share your thoughts. Sometimes during this discussion, the value is clarified, or another better idea is spawned.

2. DOING– Next, they become actively worked on, and are moved to the Doing portion of the board

3. DONE -  Once implementation is complete, the suggestion card is moved to the Done portion of the board.  And the team can update their tally of completed ideas. Pick a work area in the plant to focus your initial team on.

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SharePoint system for collecting Suggestions. 

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For more information about the JIPM TPM Framework and TPM Tools See my new book:

TPM for Executives and Managers 

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