Manage a Total Productive Maintenance Program Successfully

The Total Productive Maintenance (TPM) program is a comprehensive methodology that enables companies with equipment to maximize their effectiveness, and productivity by eliminating losses, educating their workforce and revitalizing the concept of teamwork. This provides the basics of a successful management and implementation of a TPM program.

Steps

1. Get the support from Top Management: This is essential to make the implementation as smooth as possible. Thorough investigation of the resources for the program are needed to assure that management will not stop halfway through the program. There needs to be a public resolve statement from management to spearhead the company in that direction!
2. Train the management and begin the campaign for the program: All managerial staff of the same level are scheduled together to be trained. Front line associates can be given a general slide show presentation to briefly explain the process. In depth training for a general population can become wasteful at the beginning. Nutshell training sessions for associates will be given later.
3. Form the TPM "Office" and "Infrastructure" that will support the implementation: There are variations in TPM as to the number of Pillars that should be implemented. Generally, there are 4 main Pillars are others are auxiliary.
4. Create Benchmarks, TPM Principles and Targets: In order to achieve a common goal, people must know from where they are starting, plus where they are going. Some need to be Plant wide goals, others are more team specific in how they will contribute to the plant wide goal.
5. Prepare a Master Plan for implementing the program: This includes specific activities that each Pillar will undertake to make strides forward. # Kickoff the TPM Program: Make a big statement when the organization decides to start such an effective program. Since many associated entities will be affected by the implementation of such program; they should be invited to witness the scope of the challenge ahead of them. Among the guests, there should be customers, suppliers, affiliated companies and even local community dignitaries.
6. Establish Focused Improvement Pillar: Project-team and small group activities to identify opportunities and provide solutions to gain results.
7. Implementing Autonomous Maintenance Pillar Teams with auditing certification.
8. Planned Maintenance Pillar to Support the other Pillars.
9. Training and Education Pillar to Skill up the Maintenance and Front Line associates
10. Establish Early Equipment Management Pillar System for New Equipment or Product Launches by focusing on making equipment easy to maintain and products easy to make
11. Establish the Quality Maintenance Pillar to create and sustain conditions where defects do not occur
12. Establish Office & Indirect Systems Improvement Pillar to grasp the backbone of the administration of the business and gain improvements in this area as well.
13. Establish Safety, Health and Environmental Pillar to control systems in the reduction of incidents to create systems for zero safety and environmental incidents.
14. Complete implementation of TPM and meet JIPM requirements to test for award

Tips

• The Japanese Institute of Plant Maintenance has broadly experienced consultants that visit your worksite to evaluate and coach you along the way, plus provide initial and transitional training for a successful implementation.
• The use of an outside consultant is helpful

Warnings

• Implementing TPM without Top Management support can result in frustration of workforce, loss of morale and credibility. Even loss of job if results depend on performance and delivery of results.
• TPM is not for the faint at heart or at pocket. TPM is a hands-on job and many at times requires top level management to roll up their sleeves and get dirty to lead the workforce in a cleaning activity. There is also an expected set of expenses that come with the implementation of the program, especially when using outside consultants.
• Cutting corners to save a little in financials will give you "cut corners" results.
• ----

Related Articles

• Be Popular at Your Office Job
• Deal With a Rude, Arrogant and Mean Subordinate
• Create an Urban Emergency Evacuation Kit for Work

References

• Juan C. Lopez - JIPM Certified TPM Instructor

See also

• Create a Productive Working Environment
• Be Appointed to a Board of Directors
• Become a Better and Effective Team Leader
• Set Up an Employee Assistance Program (EAP)
• Retain Good Employees
• Be an Artist Manager
• Build a Management Team
• Use an In Basket
• Write an Employee Handbook
• Plan an Employee Retreat

Read more ...

What links here

• Create Multiple Income Streams
• Make a Training Plan
• Start an Employee Wellness Program
• Make Employees Feel Secure