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TPM for lean manufacturing | lean tools

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Table of contents

1. TPM Concept
2. TPM Definition
3.  TPM Philosophy
4. TPM Essence
5. Improvement lead to real benefits
6 .Case of small amount of work
7.TPM organization
8. TPM History
9.TQC&TPM
10. Step 12 of the TPM program
11.8 main pillars of TPM
12. Participation of all employees activities
13. TPM Promotion Organization
14. Case of TPM promotion organizations
15.  TPM basic policy and Goal
16. Ask the machine

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TPM for lean manufacturing | lean tools

  1. 1. 1 TPM for lean manufacturing Chap1.TPM Concept Quote From :TPM Deployment program TPM encyclopedia Keyword Book (Japan Institute of Plant Maintenance) Created by Japanese Gemba Kaizen Web
  2. 2. 2 1.TPM Concept 1.1 TPM Definition ·········P3 1.2 TPM Philosophy ·········P4 1.3 TPM Essence ·········P5 1.4 Improvement lead to real benefits ·····P6 1.5 Case of small amount of work ··P7 1.6 TPM organization ·········P8 1.7 TPM History ·········P9 1.8 TQC&TPM ·········P10 1.9 Step 12 of the TPM program ·······P11 1.10 8 main pillars of TPM ·········P13 1.11 Participation of all employees activities ··P14 1.12 TPM Promotion Organization ·········P15 1.13 Case of TPM promotion organizations ·P16 1.14 TPM basic policy and Goal ·········P17 Ask the machine
  3. 3. 3 1.1 TPM definition ・ Establishing a corporate culture that will maximize production system effectiveness, ・ Organizing a practical shop-floor system to prevent losses before they occur throughout the entire production system life cycle, with aview to achieving zero accidents, zero defects and zero breakdowns, ・Involving all the functions of an organization including production,development, sales and management ・ Involving every employee, from top management down to front- line operators, and ・ Achieving zero losses through the activities of “overlapping small groups. Preventive maintenance tackle on with the participation of all employees
  4. 4. 4 1.2 TPM Philosophy QC:Activities to reduce the loss →can not be zero Waiting activities ・・・ From the occurrence of failure then analysis, measures,improvement. TPM:Activities to prevent loss Activity before the occurrence of the failure →can be a zero. Proactive improvement activities ・・・ Analysis before failure occurs, measures, improvement My God! Failure! TPM is Activity before the occurrence of the failure Hence you can be a zero.
  5. 5. 5 1.3 TPM Essence Unprofitable company is working on a managing the results。
  6. 6. 6 1.4 Improvement lead to real benefits Bottleneck process improvement is the highest priority
  7. 7. 7 1.5 Case of small amount of work Profits by Staff cuts 3→1 Staff cuts
  8. 8. 8 1.6 TPM organization Participation of all employees
  9. 9. 9 1.7 TPM History The TPM's definition was established in 1971 as TPM was first introduced in industry. The initial emphasis of TPM was primarily on the production floor, but as the focus shifted to the company-wide implementation, a new TPM definition was introduced in 1989. While the new definition emphasizes “company-wide TPM," the old definition focused on “TPM for the production sector. TPM stands for total productive maintenance. It was first advocated by the Japan Institute of Plant Engineering (JIPE), the forerunner of the present Japan Institute oi Plant Maintenance (JIPM). TPM has been developed into the overall, total-company plant maintenance, unique to Japan, based on productive maintenance (PM), introduced from the U.S. At the initial stage of TPM advocacy, TPM centered on the production sector. Break away From I make and you repair → Preservation of the participation of all
  10. 10. 10 1.8 TQC and TPM TPM is INPUT Type We can maintain that failure does not occur Work Site Reality ActualGoods Sangen Principle
  11. 11. 11 1.9 Step 12 of the TPM program
  12. 12. TPM is implemented through 12 steps, and these programs are called “TPM implementation program.“ The TPM implementation program can be divided as follows: - Preparatory stage for introduction — Steps l to 5 - introduction stage —— Step 6: Kickoff ot TPM - Execution stage — Steps 7 to 11 - Penetration stage —— Step 12 The period for the preparatory stage for introduction varies in accordance with the corporate scale, but generally it is executed for about six months, by providing introductory training and setting targets thoroughly. Subsequently, a kickoff meeting —— Step 6 ~ is held on a big scale. The execution stage addresses the execution of the “eight pillars for of TPM implementation.” At the penetration stage, “TPM award" screening is applied. Generally, about three years elapse between the kickoff and the undergoing of “TPM award examination." 12
  13. 13. 13 1.10 8 main pillars of TPM Production sector leading role The principal activities of TPM consist of eight items; hence, they are referred to as “eight pillars for TPM implementation."
  14. 14. 14 1.11 Participation of all employees Leave things to others→Not succeed one hundred percent(100%) subcontracting Reduce failure rate! Reduce failure rate! Reduce failure rate! Reduce failure rate! Plant manager Assistant manager team leader director manager Person in charge
  15. 15. 15 1.12 TPM Promotion Organization Administrator Also form a small group
  16. 16. 16 1.13 Case of TPM Promotion organization
  17. 17. 17 1.14 TPM basic policy and Goal Clarification of policies and objectives
  18. 18. 18 Thank you for watching the show. Please read the next chapter at My Home Page and I hope Like us on Facebook Regards. Here my personal site→Japanese Gemba Kaizen Web my firm site →crane techno consultanting

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