Total productive maintenance (TPM) is a comprehensive approach to equipment maintenance that aims to maximize the efficiency and effectiveness of production processes. It originated in Japan and has been widely adopted by manufacturing industries worldwide. TPM is built on the foundation of eight fundamental pillars, each of which plays a crucial role in achieving the overall goal of minimizing equipment downtime, reducing defects, and optimizing productivity. These eight pillars are:
- Focused Improvement (FI)/ Kobetsu Kaizen
- Autonomous Maintenance (AM)/ Jishu Hozen
- Planned Maintenance (PM)/ Keikaku Hozen
- Quality Maintenance (QM)/ Hinshitsu Hozen
- Training and Development (T&D)/ Kyoiku Kunren
- Early Equipment Management (EEM)/ Shoki Kanri
- Administrative and Office TPM (AOTPM)/ Jimu TPM
- Safety, Health and Environment (SHE)/ Anzen Eisei Kankyo)
Let's take a look over each pillar of the TPM to understand in brief.
1. FOCUSED IMPROVEMENT (FI)/ KOBETSU KAIZEN: -
Focused improvement emphasizes continuous improvement efforts aimed at identifying and eliminating the root causes of inefficiencies of equipment defects and losses. It involves the techniques like Kaizen, and problem-solving to enhance the overall equipment effectiveness.
2. AUTONOUMOUS MAINTENANCE (AM)/ JISHU HOZEN: -
This pillar focuses on empowering operators to take responsibility for routine maintenance tasks. By training and involving operators in maintenance process, the equipment stays in optimal condition, leading to reduced breakdowns and increased productivity.
3. PLANNED MAINTENANCE (PM)/ KEIKAKU HOZEN: -
Planned maintenance involves scheduling regular maintenance activities based on equipment performance data and historical analysis. By conducting preventive maintenance, businesses can address potential issues before they escalate, ensuring equipment reliability and longevity.
4. QUALITY MAINTENANCE (QM)/ HINSHITSU HOZEN: -
It emphasizes the importance of maintaining product quality throughout the manufacturing process. By preventing defects, and ensuring consistent quality standards, businesses can reduce waste, enhance customer satisfaction, and maintain a competitive edge in the market.
5. TRAINING AND DEVELOPMENT (T&D)/ KYOIKU KUNREN: -
TPM requires a well-trained workforce capable of operating, maintaining, and troubleshooting equipment effectively. This pillar focuses on providing training and skill development opportunities to employees, ensuring they have the knowledge and expertise necessary for optical equipment performance.
6. EARLY EQUIPMENT MANAGEMENT (EEM)/ SHOKI KANRI: -
EEM focuses on integrating maintenance considerations right from the equipment design and procurement stages. By involving maintenance teams early in the equipment life cycle, potential issues can be anticipated and addressed, leading to improved reliability and reduced maintenance costs.
7. ADMINISTRATIVE AND OFFICE TPM (AOTPM)/ JIMU TPM: -
TPM is not limited to the shop floor; it extends to administrative and office functions as well. AOTPM emphasizes applying TPM principles to office processes, aiming to eliminates inefficiencies, reduce paperwork and enhance overall office productivity.
8. SAFETY, HEALTH, AND ENVIRONMENT (SHE)/ ANZEN EISEI KANKYO: -
Safety, Health and Environment are paramount concerns in any workplace. This pillar emphasizes creating a safe and healthy work environment while minimizing the impact of operations on the environment. By ensuring the well-being of employees and environmental sustainability, businesses can uphold their social responsibilities and build a positive corporate image.
These eight pillars serve as the foundation of TPM guiding organizations in their journey towards achieving operational excellence, increased productivity, and enhance competitiveness in the global market.
Watch this video to learn all 8 Pillars of TPM in detail
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