12 Steps of TPM Implementation | How to Implement TPM?

How to Implement TPM (Total Productive Maintenance)?

Introduction of TPM

→ TPM stands for "Total Productive Maintenance" and its a strong relationship between Productivity and Maintenance.

→ It tells us about the care of our equipment can give us good productivity.

→ TPM is all about ownership and continual improvement.

→ It empowers the machine operator to maintain and operate the machine in good condition.

→ Total Productive Maintenance helps organizations for Effective and Efficient Productivity.

→ The goal of TPM is zero accidents, zero breakdowns, and zero defects.

→ There is a very tough competition in today's scenario and it is increasing day by day.

→ So customers focus on Product Quality, Delivery Time, and Cost of Product.

→ To fulfill customer's requirements we need to implement various systems at our site also.

→ Refer to this article for Detailed Presentation of Eight Pillars of Total Productive Maintenance.

→ TPM focuses on improve planning and scheduling.

→ Also, focus on different wasteful activities like 16 Major Losses of Production and 6 Big Losses of OEE.

→ Visit this article: 6 Big Losses of OEE that will help us to improve our productivity.

→ Also, visit this article: 16 Major Losses of Production that will help us to improve profitability.

→ Also, refer to this article: Complete Overview of TPM Explained with Complete Details


Benefits of TPM (Total Productive Maintenance)

→ The major benefits are mentioned below:

→ Increase Productivity and OEE (Overall Equipment Efficiency).

→ Reduce customer complaints.

→ Reduce production cost.

→ Increase customer satisfaction by delivering the right Quality Product, at right time with the right cost-benefit of the customer. 

→ Reduce accidents.

→ Morale and Motivation improve an employee's attitude change of operator from "We operate you maintain" to "We operate we maintain".


12 Steps of TPM Implementation

→ 12 Steps for Implementation TPM are mentioned below.

  1. Declaration by top management to introduce TPM
  2. Education and training about the TPM campaign
  3. Formation of the committee for TPM promotion in the organization
  4. The setting of basic TPM principles and targets
  5. Preparation of a master plan for implementing TPM
  6. Kickoff of TPM
  7. Establishment of a system for improving the efficiency of the production
  8. Establishment of an initial control system for new product and new equipment
  9. Establishment of quality maintenance systems
  10. Establishment of a system for improving the efficiency of administration and other departments
  11. Establishment of systems for the control of safety, health, and the environment
  12. Complete implementation of TPM and level improvement

How to Implement TPM


Step 1: Declaration by top management to introduce TPM

→ The declaration of the top management about the implementation of TPM in the the organization should be communicated across the organization by a common communication medium.

→ The common communication medium may be notice board, email communication, or internal newsletter.


Step 2: Education and training about the TPM

→ TPM training needs to provide to all employees of the organization.

→ As per the grade and responsibility, the training course needs to design and training should be given.

→ We can give training in any medium like classroom training, virtual training, video lecture, etc.


Step 3: Formation of the committee for TPM promotion in the organization

→ The committees and specialized subcommittees need to be formed for the promotion of the TPM within the organization.

→ The promotion activity can be done with the help of various publications like newsletters, articles, videos, posters, etc.


Step 4: Setting of basic TPM principles and targets

→ Business objectives, benchmarks, and targets need to decide for this improvement journey.

→ As per the current scenarios we need to establish the baseline data for all the organizational KPIs.

→ The setting of SMART goals is: Specific, Measurable, Attainable/Achievable, Realistic, and Time-based.


Step 5: Preparation of a master plan for implementing TPM

→ Prepare the master plan for TPM implementation and also mention the target date and responsibilities.

→ Generally, the time period should be around 3 years but finally, it is decided by the organization.

→ The basis of the master plan, formulate the annual, quarterly, and monthly planning.


Step 6: Kickoff of TPM

→ The top management publically announces the implementation of TPM within the organization.

→ Also communicate the same to various stakeholders like customers, vendors, and various statutory and regulatory bodies.

→ Also, various stakeholders are invited during the kickoff meeting.

Total Productive Maintenance implementation activity starts from this step.


Step 7: Establishment of a system for improving the efficiency of the production

→ This step is related to improve the efficiency and effectiveness of the production.

→ For improving productivity and production efficiency we need to implement various 4 pillars of TPM at the production shop floor in this step.

  • Kobetsu-Kaizen (Focused Improvement)
  • Jishu-Hozen (Autonomous Maintenance)
  • Planned Maintenance
  • Training & Education Pillar

(A). Implementation of Kobetsu-Kaizen or we can say that Focused Improvement.

→ In these pillars, the project team initiate various activities and workshop of small-group activities that are related to small improvements at production floor.

(B). Implementation of Jishu-Hozen (Autonomous Maintenance) pillars

→ Implement the 7 Step method of Jishu Hozen (Autonomous Maintenance).

→ Develop an autonomous maintenance program for operators.

(C). Implementation of Planned Maintenance pillars

→ Implement the various maintenance practices like corrective maintenance, periodic maintenance, predictive maintenance, etc.

→ Develop a Preventive Maintenance plan for eliminating breakdowns of equipment.

→ It will help us to maintain zero breakdowns.

(D). Implementation of Training & Education Pillar

→ Give train to all team members about the various pillars, skills, and activities.


Step 8: Establishment of an initial control system for new product and new equipment

→ In this step, we need to implement an early equipment management pillar for new product and equipment development.

→ So we can easily get rated output from equipment in a short time period.


Step 9: Establishment of quality maintenance systems

→ In this step, we need to implement the Quality Maintenance pillar.

→ It will help us maintain the zero-defect generation from the machine.


Step 10: Establishment of a system for improving the efficiency of administration

→ In this step, we need to implement the Administration & Officer TPM.

→ This pillar is related to other department's roles for supporting the production department.


Step 11: Establishment of systems for the control of safety, health, and the environment

→ In this step, we need to implement the safety, health, and environment pillar of TPM.

→ This pillar helps to maintain zero accidents.


Step 12: Complete implementation of TPM and level improvement

→ In this step, we should go for the participation of the TPM award.

→ Also, we need to improve our TPM level as per the various levels.

→ Also, we need to take strong targets for next year.

👉 Also Read:

👉 For a regular update :   
Join us (Telegram Group)
Join us (WhatsApp Group)

👉 See Also: