12 Steps of TPM Implementation: A Comprehensive Guide

tpm implementation

12 Steps of TPM Implementation: A Comprehensive Guide

Total Productive Maintenance (TPM) is a powerful strategy that aims to maximize the efficiency and reliability of equipment and machinery in a manufacturing setting. TPM doesn't just focus on maintenance; it encompasses the entire spectrum of operations. In this comprehensive guide, we will delve into the 12 essential steps of TPM implementation, providing you with a clear roadmap to enhance your organization's productivity and competitiveness.

How to implement tpm in an organization

  • TPM’s full form is ” Total Productive Maintenance “and it’s a strong relationship between Productivity and Maintenance.
  • It tells us about of our equipment can give us good productivity.
  • TPM is each about ownership and continual improvement.
  • It allows the machine operator to maintain and operate the machine in good condition.
  • Total Productive Maintenance helps company for Effective and Efficiency Productivity
  • The goal of TPM is zero accidents, zero breakdowns, and zero defects.
  • There’s very tough competition in today’s scenario and it’s adding day by day.
  • So client concentrates on Product Quality, Delivery Time, and Cost of Product.
  • To fulfill the client’s conditions we need to apply several systems at our place also.
  • Relate to this structure for a Detailed presentation of  8 Pillars of Total Productive Maintenance.
  • TPM focuses on improvement planning and scheduling.
  • Also, concentrate on different wasteful activities like 16 Major Losses of Production and 6 Big Losses of OEE.

Benefits of Total Productive Maintenance

  • The major benefits are mentioned below
  • Increase Productivity and OEE (Overall Equipment Efficiency)
  • Reduce client complaints.
  • Reduce production costs.
  • Increase client satisfaction by delivering the right Quality Product, at the right time with the right cost-benefit for the client.
  • Reduce accidents.
  • Morale and motivation improve an employee’s attitude change of operator from
  • “We operate you maintain “to” We operate we maintain”.

12 steps of TPM Implementation

→ 12 steps for the Implementation of TPM are mentioned below.

  1.  Declaration by top management to introduce TPM
  2. Education and training about the TPM campaign
  3. Development of the committee for TPM promotion in the association
  4. The setting of basic TPM principles and targets
  5. Preparation of a master plan for implementing TPM
  6. Kick-off of TPM
  7. Establishment of a system for improving the efficiency of the production
  8. Establishment of an initial control system for new products and new outfit
  9. Establishment of quality maintenance systems
  10. Establishment of a system for improving the efficiency of administration and Other departments
  11. Establishment of systems for the control of safety, health, and the environment
  12. Complete implementation of TPM and level improvement

Step - 1 Declaration by top management to introduce Total Productive Maintenance

  • The Declaration of the top management about the implementation of TPM in the company should be communicated across the association by
    a common communication medium.
  • The common communication medium may be a notice board, email communication, or an internal newsletter.

Step - 2 Education and training about the Total Productive Maintenance

  • TPM training needs to give to all workers of the company.
  •  As per the grade and responsibility, the training course needs to design and training should be given.
  •  We can give training in any medium like classroom training, virtual training, videotape lecture, etc.

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.

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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.

5s tpm implementation

Before we dive into the intricacies of 5S TPM implementation, let's grasp the basics. 5S TPM is a systematic approach aimed at optimizing production processes.

The term '5S' originates from five Japanese words, all starting with 'S,' which represent the fundamental principles of this methodology: Seiri (Sort), Seiton (Set in order), Seiso (Shine), Seiketsu (Standardize), and Shitsuke (Sustain).

On the other hand, TPM focuses on maintaining and improving equipment to ensure maximum efficiency and effectiveness.

Read More :

  1. Abnormalities TPM
  2. What is TPM
  3. Kaizen
  4. One point lesson
  5. tpm training plan

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