TPM Implementation

12 STEPS OF TPM IMPLEMENTATION

Step - 3 Formation of the committee for 

TPM promotion in the association

• A committee and specialized subcommittee need to be formed for the promotion of the TPM within the company.

•  The promotion activity can be done with the help of several publications like newsletters, papers, videos, poster, etc.

Step - 4 - Setting of Basic TPM Principles and Targets

•  Business objectives, marks, and targets need to decide for this improvement journey.

•  As per the current situation, we need to establish the baseline data for all the organizational KPIs.

•  The setting of SMART goals is Specific, Measurable, Attainable/ Achievable, Realistic, and Time- based.

Step - 5 - Preparation of a Master Plan for implementing

• Prepare the master plan for TPM implementation and also mention the target date and responsibilities.

• Generally, the time period should be around 3 years but now, it’s decided by the company.

• The base of the master plan, formulates the periodic, daily, and yearly planning.

Step - 6 - Kick-off of Total Productive Maintenance

• The top management publicly announces the implementation of TPM within the company.

• Also communicate the same to several stakeholders like clients, merchandisers, and several statutory and nonsupervisory bodies. 

• Also, several stakeholders are invited during the kick-off meeting. 

• Total Productive Maintenance implement exercise starts from this step

Step - 7 - Establishment of a system for perfecting the effectiveness of the production

• This step is related to improving the efficiency and effectiveness of production.

•  For improving productivity and production efficiency we need to implement various 4 pillars of TPM at the production shop floor in this step.

– Kobetsu-Kaizen (focus improvement)

– Jishu-Hozen (Autonomous Maintenance)

– Planned Maintenance

– Training & Education Pillar

1. Implementation of Kobetsu-Kaizen or we can say that focused improvement

• In these pillars, the project team initiate several activities and a Workshop on small-group activities that are related to small improvements at the production floor.

2. Implementation of Jishu-Hozen (Autonomous Maintenance) pillars

• Apply the 7-Step system of Jishu Hozen (Autonomous Maintenance).

• Develop an independent Maintenance program for drivers.

3. Implementation of Planned Maintenance pillars

• Apply colorful Maintenance practices like corrective Maintenance, Periodic Maintenance, predictive Maintenance, etc.

• Develop a Preventative Maintenance plan for barring breakdowns of equipment.

• It’ll help us to maintain zero breakdowns.

4. Implementation of Training & Education Pillar

• Give train to all team members about every pillars, skill, and activity

Step - 8 - Establishment of an initial control system for new products and new equipment

•  In this step, we need to implement an early equipment management pillar for new product and equipment development.

• So, we can fluently get rated output from equipment in a short time period.

Step - 9 -  Establishment of quality Maintenance systems

•  In this step, we need to apply the Quality Maintenance pillar.

•  It’ll help us maintain the zero-defect generation from the machine.

Step - 10 -  Establishment of a system for improving the efficiency of administration

• In this step, we need to implement the Administration & Officer TPM.

• This pillar is related to other departments’ places for supporting the Production department.

Step - 11 -  Establishment of systems for the control of safety, health, and the Environment

•  In this step, we need to apply the safety, health, and Environment pillar of TPM.

•  This pillar helps to maintain zero accidents.

Step - 12 -  Complete Implement and Level Improvement

•   In this step, we should go for participation of the TPM award.

•  Also, we need to improve our TPM level as per Several situations.

• Also, we need to take strong targets for next year.