Total Productive Maintenance (TPM)
Total Productive Maintenance (TPM) Prevent inefficiencies and enhance safety through the power of the TPM System
Contents Introduction
4
The 8 Pillars of Total Productive Maintenance
5
Overall Equipment Effectiveness
9
Total Productive Maintenance: Step by Step
10
Roadblocks to TPM Success
12
Facility Marking Workbook
14
1-866-777-1360 | creativesafetysupply.com Creative Safety Supply is the leader in visual safety. We aim to help you create a safer, more efficient and compliant workplace using visual tools such as floor marking tapes, signs, labels, 5S & Lean products, and safety merchandise. ©2017 Creative Safety Supply, All Rights Reserved
Find and follow us
For additional information about Total Productive Maintenance plus industry updates, helpful product recommendations, and more:
creativesafetysupply.com/tpm
More info: Total Productive Maintenance
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Introduction Total Productive Maintenance is a comprehensive, holistic strategy for equipment maintenance that seeks to improve productivity by reducing downtime, speed losses, and defects, while also promoting the value of a safe, organized working environment. More than guidelines on how to maintain equipment, TPM aims to instill a feeling of responsibility for equipment in all employees. First developed in 1969 by Seiichi Nakajima at Toyota Group company Nippon Denso, Total Productive Maintenance was initially designed to reduce waste in the auto industry, but it quickly became apparent that TPM’s simple, straightforward tenets apply to almost any business where equipment failures can lead to lost productivity. Dubbed the “Father of Total Productive Maintenance,” Nakajima once described TPM as “a company-wide program for improving equipment effectiveness -- something that maintenance alone could not do.” Owing to their similar origins and core philosophies, Total Productive Maintenance is often viewed as an extension of the 5S method of workplace organization. While 5S aims to reduce wasted time and materials in recurrent processes, TPM reduces waste caused by equipment malfunctions and required maintenance. In concert, these two methodologies work to eliminate all avoidable waste, thus increasing productivity and, inevitably, profits.
Introduction
creativesafetysupply.com/tpm
The 8 Pillars of Total Productive Maintenance Total Productive Maintenance is often broken down into eight distinct pillars focused on proactive methods of improving equipment reliability and, in turn, productivity. Each of these pillars rests atop a foundation formed by the implementation of 5S methodologies in the workplace.
EARLY EQUIPMENT
1 MAINTENANCE
5 QUALITY INTEGRATION
2 JISHU HOZEN
6 TRAINING
3 KAIZEN
7 OFFICE TPM
PLANNED
4 MAINTENANCE
SAFETY, HEALTH &
8 ENVIRONMENT
EARLY EQUIPMENT MANAGEMENT Early Equipment Management (or EEM) seeks to instill a high-level of efficiency in a process from the start. Though EEM usually requires careful planning, as the popularity and effectiveness of EEM has grown, equipment manufacturers have begun to design machines with an eye toward a customer’s autonomous and planned maintenance standards.
The 8 Pillars of Total Productive Maintenance
creativesafetysupply.com/tpm
JISHU HOZEN Jishu Hozen is a Japanese term that roughly means, “autonomous maintenance.” This pillar is aimed at teaching employees how to maintain the equipment they use each day. Not only does this foster a sense of personal responsibility for the upkeep and day-to-day maintenance of the equipment, it also frees up skilled maintenance workers to focus on more technical repairs that require specialized training. Unlike most other workplace improvement initiatives, autonomous maintenance can’t be mandated, but instead will blossom organically in organizations where the other core tenets of TPM have been put into place.
KAIZEN Another Japanese concept, kaizen refers to the continuous practice of making small improvements that, over time, add up to tremendous benefits. While Kaizen relies heavily on discipline and long-term planning, it has extremely minor up front costs, making kaizen an incredibly cost-effective means of improving a business. Helpfully, Kaizen doesn’t just apply to equipment maintenance. It can be employed effectively in any aspect of a business where small improvements can be found and acted upon.
PLANNED MAINTENANCE This pillar aims to shift maintenance efforts from reactive to proactive by utilizing trained maintenance staff to instruct employees on how to maintain equipment on a day-to-day basis. Complicated repairs will still require specialized skills, but by offering equipment operators a basic grounding in how their equipment functions, you empower them to make small repairs and adjustments as they become necessary. This reduces equipment downtime, improves efficiency, and gives each employee a sense of ownership that directly translates into a desire to care for equipment. The 8 Pillars of Total Productive Maintenance
creativesafetysupply.com/tpm
QUALITY INTEGRATION Where Planned Maintenace aims to improve equipment maintenance procedures, Quality Integration focuses on creating the highestquality product possible by reducing or eliminating problems in the manufacturing process. Establishing a solid understanding of which parts of equipment impact product quality should be the first step, followed by careful efforts to remove existing quality concerns. Once existing quality concerns have been eliminated, potential future quality concerns should be identified and eliminated.
TRAINING The goal of this pillar is training employees on not just how to maintain equipment, but also why maintenance is important. The ultimate goal is to create “a factory full of experts” who not only improve productivity by virtue of their comprehensive knowledge, but who can also train others on how to maintain the workplace. Training empowers employees to rapidly fix problems as they arise while reinforcing each employee’s sense of personal responsibility toward their role in the business.
Learn more about Total Productive Maintenance at
creativesafetysupply.com/tpm
The 8 Pillars of Total Productive Maintenance
creativesafetysupply.com/tpm
OFFICE TPM As its name suggests, Office TPM seeks to bring the gradual, incremental improvements of Total Productive Maintenance from the shop into an office setting to improve productivity and efficiency in administrative tasks. The most common forms of productivity loss that Office TPM aims to counter are: • Processing loss • Cost loss including in areas such as procurement, accounts, marketing, sales leading to high inventories • Communication loss • Idle loss • Set-up loss • Accuracy loss • Office equipment breakdown • Communication channel breakdown, telephone and fax lines
A recent study found that inefficient communications cost small companies an average of $420,000 annually, while large companies lose
$62.4 million
each year.
• Time spent on retrieval of information • Non availability of correct online stock status
Source: Society for Human Resource Management www.shrm.org
• Customer complaints due to logistics • Expenses on emergency dispatches/purchases
SAFETY, HEALTH, AND ENVIRONMENT This pillar focuses on creating a workplace that is safe and orderly, that will not be disrupted by common processes or procedures. The ultimate goal is zero accidents, zero fires, and zero negative effects on employee health.
The 8 Pillars of Total Productive Maintenance
creativesafetysupply.com/tpm
Overall Equipment Effectiveness Overall Equipment Effectiveness is a handy framework for measuring efficiency by dividing a process into three factors:
AVAILABILITY
Availability details planned and unplanned stoppage. An availability score of 100% means the process in question is running continuously during production time.
PERFORMANCE
Performance examines slow cycles and minor stops. A performance score of 100% dictates that when the process is running, it continuously runs at full speed.
QUALITY
Quality takes into account defects, both in products created and in equipment. A quality score of 100% means there are zero defects, and that only high-quality products are being created.
There are six major kinds of loss that consistent monitoring of Overall Equipment Effectiveness can protect an organization from:
Unplanned production stops
Slowed production
Time lost due to setup and adjustments
Production defects
Reduced production yield
Small stops
Overall Equipment Effectiveness
creativesafetysupply.com/tpm
Total Productive Maintenance: Step By Step Now that you’ve learned about the ideas that make up TPM, it’s time for something more practical: A step by step walkthrough of how TPM might be implemented in an organization.
STEP 1
Identify Your Target Area
Though it’s tempting to employ TPM throughout a facility all at once, it’s often far more effective to integrate TPM in one or two pieces of equipment to begin with, then gradually expand TPM efforts as needed. Determining the best place to start can be difficult, but most organizations should focus initially on those pieces of equipment that are the easiest to improve. Not only does this provide a quick win and potential improvements in efficiency and productivity, it also rapidly demonstrates the value of TPM to others in the organization which can be critical for earning their support.
STEP 2
Make Your Equipment Shine
This step focuses on restoring equipment to ideal operating conditions, which makes implementing autonomous maintenance procedures significantly easier. Not just focused on equipment, this step can also include light training to ensure that all equipment operators are at the same level of competency.
TPM: Step by Step
creativesafetysupply.com/tpm
STEP 3
Start Measuring Overall Equipment Effectiveness
With equipment running at the desired level, a baseline OEE measurement can be created. This can be done manually or by using an automated program, but regardless of the method, the goal is the same: Creating a point of reference against which you can measure increases and decreases in OEE as time goes on. Regular comparisons against this baseline will make it easy to find and eliminate issues with equipment.
STEP 4
Address Losses
Once a problem is identified, it’s time to find a solution. Smaller losses may only require a design tweak or slight alteration to a process, but big losses should be addressed by a small team of operators, maintenance personnel, and supervisors armed with the best tools and understanding of the equipment. Ideally, an organization will only have to solve these big losses once, as the implementation of TPM will prevent them from occurring in the first place.
STEP 5
Adopt Proactive Maintenance Techniques
Having fixed all major problems and designed a system for monitoring effectiveness, it’s now time to implement a maintenance regimen that will ensure those issues won’t come back. In this step, it’s important to identify which components of equipment are most likely to fail, then adopt a maintenance schedule based on the speed at which these components wear. Alternately, a time-based schedule (based on calendar time OR total production time) may be used, though that requires more attentive monitoring to counteract any flaws that might crop up between schedule maintenance efforts.
TPM: Step by Step
creativesafetysupply.com/tpm
Roadblocks to TPM Success Perhaps the most powerful of the “lean tools,” Total Productive Maintenance is also often the most difficult to properly implement in an existing company. Two reasons exist for this:
TPM can require significant cultural changes that impact a wide swath of a company’s employees -- far more than other lean methods. As a result, it may take time to establish widespread trust in the benefits TPM offers.
Equipment maintenance is often a secondary consideration for a company, particularly if management views maintenance efforts as a necessary evil instead of an opportunity to improve productivity.
Total Productive Maintenance Is Not Total Quality Management Often confused due to their similar acronyms, Total Productive Maintenance is not Total Quality Management. TQM is a philosophy that seeks to align divisions in an organization toward a common goal of meeting customers’ needs. TPM, meanwhile, is a strategy for improving efficiency by involving equipment operators in the ongoing maintenance of their machines.
Roadblocks to TPM Success
creativesafetysupply.com/tpm
For additional information about Total Productive Maintenance plus industry updates, helpful product recommendations, and more:
creativesafetysupply.com/tpm
More info: Total Productive Maintenance
creativesafetysupply.com/tpm
You may also be interested in:
FACILITY MARKING WORKBOOK
FREE DOWNLOAD creativesafetysupply.com/guides
This workbook walks you through your facility with handy forms, helping you evaluate where you need visual safety markings like floor tape, floor signs, and wall signs. It covers: •
OSHA Compliance and Safety
•
Pipe Marking, Electrical and other common hazards
•
Warehouse and Floor Marking
•
PPE and visual safety cues
•
Warehouse marking and more
BECOME AN EXPERT.
FREE LEAN & SAFETY RESOURCES We offer free informative resources covering a wide range of industrial topics. Whether you want to learn about something new or just brush up on a subject, visit our Resource Center today.
Dozens of e-books & guides Articles and tips 2 free safety podcasts Infographics Lean and Safety Blog
visit creativesafetysupply.com/resources Chapter x
creativesafetysupply.com/tpm
CREATE A SAFER, SMARTER FACILITY.
Creative Safety Supply is your one stop shop for... Label & Sign Printers
Virtual Floor Signs
Lean & Safety Posters
Foam Tool Organizers
Pallet Alignment Markers
Training Books & DVDs
5S Tools & Supplies
Industrial Floor Signs
Spill Kits & Sorbents
Ready-to-Order Labels
Floor Marking Tapes
Facility Branding
...and much more! Shop online now at creativesafetysupply.com or call 1-866-777-1360 Chapter x
creativesafetysupply.com/tpm
Contents Introduction
4
The 8 Pillars of Total Productive Maintenance
5
Overall Equipment Effectiveness
9
Total Productive Maintenance: Step by Step
10
Roadblocks to TPM Success
12
Facility Marking Workbook
14
1-866-777-1360 | creativesafetysupply.com Creative Safety Supply is the leader in visual safety. We aim to help you create a safer, more efficient and compliant workplace using visual tools such as floor marking tapes, signs, labels, 5S & Lean products, and safety merchandise. ©2017 Creative Safety Supply, All Rights Reserved
Find and follow us
For additional information about Total Productive Maintenance plus industry updates, helpful product recommendations, and more:
creativesafetysupply.com/tpm
More info: Total Productive Maintenance
creativesafetysupply.com/tpm
Introduction Total Productive Maintenance is a comprehensive, holistic strategy for equipment maintenance that seeks to improve productivity by reducing downtime, speed losses, and defects, while also promoting the value of a safe, organized working environment. More than guidelines on how to maintain equipment, TPM aims to instill a feeling of responsibility for equipment in all employees. First developed in 1969 by Seiichi Nakajima at Toyota Group company Nippon Denso, Total Productive Maintenance was initially designed to reduce waste in the auto industry, but it quickly became apparent that TPM’s simple, straightforward tenets apply to almost any business where equipment failures can lead to lost productivity. Dubbed the “Father of Total Productive Maintenance,” Nakajima once described TPM as “a company-wide program for improving equipment effectiveness -- something that maintenance alone could not do.” Owing to their similar origins and core philosophies, Total Productive Maintenance is often viewed as an extension of the 5S method of workplace organization. While 5S aims to reduce wasted time and materials in recurrent processes, TPM reduces waste caused by equipment malfunctions and required maintenance. In concert, these two methodologies work to eliminate all avoidable waste, thus increasing productivity and, inevitably, profits.
Introduction
creativesafetysupply.com/tpm
The 8 Pillars of Total Productive Maintenance Total Productive Maintenance is often broken down into eight distinct pillars focused on proactive methods of improving equipment reliability and, in turn, productivity. Each of these pillars rests atop a foundation formed by the implementation of 5S methodologies in the workplace.
EARLY EQUIPMENT
1 MAINTENANCE
5 QUALITY INTEGRATION
2 JISHU HOZEN
6 TRAINING
3 KAIZEN
7 OFFICE TPM
PLANNED
4 MAINTENANCE
SAFETY, HEALTH &
8 ENVIRONMENT
EARLY EQUIPMENT MANAGEMENT Early Equipment Management (or EEM) seeks to instill a high-level of efficiency in a process from the start. Though EEM usually requires careful planning, as the popularity and effectiveness of EEM has grown, equipment manufacturers have begun to design machines with an eye toward a customer’s autonomous and planned maintenance standards.
The 8 Pillars of Total Productive Maintenance
creativesafetysupply.com/tpm
JISHU HOZEN Jishu Hozen is a Japanese term that roughly means, “autonomous maintenance.” This pillar is aimed at teaching employees how to maintain the equipment they use each day. Not only does this foster a sense of personal responsibility for the upkeep and day-to-day maintenance of the equipment, it also frees up skilled maintenance workers to focus on more technical repairs that require specialized training. Unlike most other workplace improvement initiatives, autonomous maintenance can’t be mandated, but instead will blossom organically in organizations where the other core tenets of TPM have been put into place.
KAIZEN Another Japanese concept, kaizen refers to the continuous practice of making small improvements that, over time, add up to tremendous benefits. While Kaizen relies heavily on discipline and long-term planning, it has extremely minor up front costs, making kaizen an incredibly cost-effective means of improving a business. Helpfully, Kaizen doesn’t just apply to equipment maintenance. It can be employed effectively in any aspect of a business where small improvements can be found and acted upon.
PLANNED MAINTENANCE This pillar aims to shift maintenance efforts from reactive to proactive by utilizing trained maintenance staff to instruct employees on how to maintain equipment on a day-to-day basis. Complicated repairs will still require specialized skills, but by offering equipment operators a basic grounding in how their equipment functions, you empower them to make small repairs and adjustments as they become necessary. This reduces equipment downtime, improves efficiency, and gives each employee a sense of ownership that directly translates into a desire to care for equipment. The 8 Pillars of Total Productive Maintenance
creativesafetysupply.com/tpm
QUALITY INTEGRATION Where Planned Maintenace aims to improve equipment maintenance procedures, Quality Integration focuses on creating the highestquality product possible by reducing or eliminating problems in the manufacturing process. Establishing a solid understanding of which parts of equipment impact product quality should be the first step, followed by careful efforts to remove existing quality concerns. Once existing quality concerns have been eliminated, potential future quality concerns should be identified and eliminated.
TRAINING The goal of this pillar is training employees on not just how to maintain equipment, but also why maintenance is important. The ultimate goal is to create “a factory full of experts” who not only improve productivity by virtue of their comprehensive knowledge, but who can also train others on how to maintain the workplace. Training empowers employees to rapidly fix problems as they arise while reinforcing each employee’s sense of personal responsibility toward their role in the business.
Learn more about Total Productive Maintenance at
creativesafetysupply.com/tpm
The 8 Pillars of Total Productive Maintenance
creativesafetysupply.com/tpm
OFFICE TPM As its name suggests, Office TPM seeks to bring the gradual, incremental improvements of Total Productive Maintenance from the shop into an office setting to improve productivity and efficiency in administrative tasks. The most common forms of productivity loss that Office TPM aims to counter are: • Processing loss • Cost loss including in areas such as procurement, accounts, marketing, sales leading to high inventories • Communication loss • Idle loss • Set-up loss • Accuracy loss • Office equipment breakdown • Communication channel breakdown, telephone and fax lines
A recent study found that inefficient communications cost small companies an average of $420,000 annually, while large companies lose
$62.4 million
each year.
• Time spent on retrieval of information • Non availability of correct online stock status
Source: Society for Human Resource Management www.shrm.org
• Customer complaints due to logistics • Expenses on emergency dispatches/purchases
SAFETY, HEALTH, AND ENVIRONMENT This pillar focuses on creating a workplace that is safe and orderly, that will not be disrupted by common processes or procedures. The ultimate goal is zero accidents, zero fires, and zero negative effects on employee health.
The 8 Pillars of Total Productive Maintenance
creativesafetysupply.com/tpm
Overall Equipment Effectiveness Overall Equipment Effectiveness is a handy framework for measuring efficiency by dividing a process into three factors:
AVAILABILITY
Availability details planned and unplanned stoppage. An availability score of 100% means the process in question is running continuously during production time.
PERFORMANCE
Performance examines slow cycles and minor stops. A performance score of 100% dictates that when the process is running, it continuously runs at full speed.
QUALITY
Quality takes into account defects, both in products created and in equipment. A quality score of 100% means there are zero defects, and that only high-quality products are being created.
There are six major kinds of loss that consistent monitoring of Overall Equipment Effectiveness can protect an organization from:
Unplanned production stops
Slowed production
Time lost due to setup and adjustments
Production defects
Reduced production yield
Small stops
Overall Equipment Effectiveness
creativesafetysupply.com/tpm
Total Productive Maintenance: Step By Step Now that you’ve learned about the ideas that make up TPM, it’s time for something more practical: A step by step walkthrough of how TPM might be implemented in an organization.
STEP 1
Identify Your Target Area
Though it’s tempting to employ TPM throughout a facility all at once, it’s often far more effective to integrate TPM in one or two pieces of equipment to begin with, then gradually expand TPM efforts as needed. Determining the best place to start can be difficult, but most organizations should focus initially on those pieces of equipment that are the easiest to improve. Not only does this provide a quick win and potential improvements in efficiency and productivity, it also rapidly demonstrates the value of TPM to others in the organization which can be critical for earning their support.
STEP 2
Make Your Equipment Shine
This step focuses on restoring equipment to ideal operating conditions, which makes implementing autonomous maintenance procedures significantly easier. Not just focused on equipment, this step can also include light training to ensure that all equipment operators are at the same level of competency.
TPM: Step by Step
creativesafetysupply.com/tpm
STEP 3
Start Measuring Overall Equipment Effectiveness
With equipment running at the desired level, a baseline OEE measurement can be created. This can be done manually or by using an automated program, but regardless of the method, the goal is the same: Creating a point of reference against which you can measure increases and decreases in OEE as time goes on. Regular comparisons against this baseline will make it easy to find and eliminate issues with equipment.
STEP 4
Address Losses
Once a problem is identified, it’s time to find a solution. Smaller losses may only require a design tweak or slight alteration to a process, but big losses should be addressed by a small team of operators, maintenance personnel, and supervisors armed with the best tools and understanding of the equipment. Ideally, an organization will only have to solve these big losses once, as the implementation of TPM will prevent them from occurring in the first place.
STEP 5
Adopt Proactive Maintenance Techniques
Having fixed all major problems and designed a system for monitoring effectiveness, it’s now time to implement a maintenance regimen that will ensure those issues won’t come back. In this step, it’s important to identify which components of equipment are most likely to fail, then adopt a maintenance schedule based on the speed at which these components wear. Alternately, a time-based schedule (based on calendar time OR total production time) may be used, though that requires more attentive monitoring to counteract any flaws that might crop up between schedule maintenance efforts.
TPM: Step by Step
creativesafetysupply.com/tpm
Roadblocks to TPM Success Perhaps the most powerful of the “lean tools,” Total Productive Maintenance is also often the most difficult to properly implement in an existing company. Two reasons exist for this:
TPM can require significant cultural changes that impact a wide swath of a company’s employees -- far more than other lean methods. As a result, it may take time to establish widespread trust in the benefits TPM offers.
Equipment maintenance is often a secondary consideration for a company, particularly if management views maintenance efforts as a necessary evil instead of an opportunity to improve productivity.
Total Productive Maintenance Is Not Total Quality Management Often confused due to their similar acronyms, Total Productive Maintenance is not Total Quality Management. TQM is a philosophy that seeks to align divisions in an organization toward a common goal of meeting customers’ needs. TPM, meanwhile, is a strategy for improving efficiency by involving equipment operators in the ongoing maintenance of their machines.
Roadblocks to TPM Success
creativesafetysupply.com/tpm
For additional information about Total Productive Maintenance plus industry updates, helpful product recommendations, and more:
creativesafetysupply.com/tpm
More info: Total Productive Maintenance
creativesafetysupply.com/tpm
You may also be interested in:
FACILITY MARKING WORKBOOK
FREE DOWNLOAD creativesafetysupply.com/guides
This workbook walks you through your facility with handy forms, helping you evaluate where you need visual safety markings like floor tape, floor signs, and wall signs. It covers: •
OSHA Compliance and Safety
•
Pipe Marking, Electrical and other common hazards
•
Warehouse and Floor Marking
•
PPE and visual safety cues
•
Warehouse marking and more
BECOME AN EXPERT.
FREE LEAN & SAFETY RESOURCES We offer free informative resources covering a wide range of industrial topics. Whether you want to learn about something new or just brush up on a subject, visit our Resource Center today.
Dozens of e-books & guides Articles and tips 2 free safety podcasts Infographics Lean and Safety Blog
visit creativesafetysupply.com/resources Chapter x
creativesafetysupply.com/tpm
CREATE A SAFER, SMARTER FACILITY.
Creative Safety Supply is your one stop shop for... Label & Sign Printers
Virtual Floor Signs
Lean & Safety Posters
Foam Tool Organizers
Pallet Alignment Markers
Training Books & DVDs
5S Tools & Supplies
Industrial Floor Signs
Spill Kits & Sorbents
Ready-to-Order Labels
Floor Marking Tapes
Facility Branding
...and much more! Shop online now at creativesafetysupply.com or call 1-866-777-1360 Chapter x
creativesafetysupply.com/tpm
