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

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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

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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

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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.

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1.3 TPM Essence
Unprofitable company is working on a managing
the results。

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1.4 Improvement lead to real benefits
Bottleneck process improvement is the highest priority

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1.5 Case of small amount of work
Profits by Staff cuts
3→１ Staff cuts

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1.6 ＴＰＭ organization
Participation of all employees

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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

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1.8 TQC and TPM
TPM is INPUT Type
We can maintain that failure does not occur
Work Site
Reality
ActualGoods
Sangen Principle

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1.9 Step 12 of the TPM program

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

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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."

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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

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1.12 TPM Promotion Organization
Administrator Also form a small group

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1.13 Case of TPM Promotion organization

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1.14 TPM basic policy and Goal
Clarification of policies and objectives

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