The twelve steps of TPM discussed here are the steps for applying TPM across the whole organisation — what is called Company-wide TPM. The work divides into main phases: the preparation phase, steps 1 to 6 · the implementation phase, steps 7 and 8 · the improvement and consolidation phase, steps 9 to 12.
Only after sufficient preparation is the TPM programme formally opened — the TPM kickoff. The preparation period varies somewhat with the size and nature of the production process, but generally runs about three to four months, from step 1 through to drawing up the TPM master plan.
The implementation phase begins immediately once the formal opening ceremony has passed, following the master plan continuously through to step 12. Having reached step 12, the company is entitled to seek out an institute to certify the results of its TPM activity. From the opening ceremony to step 12 generally takes about two and a half to three years — though where there are large numbers of employees and of machines and equipment, it may take three to five.
Five pillars in production, extending to eight across the organisation
The implementation phase means carrying out TPM in the production area only, along five pillars.
- Individual improvement
- Autonomous maintenance
- Planned maintenance
- Education and training to raise operating and maintenance skill
- Maintenance considered from the design stage
Once the work has raised production efficiency, TPM in the production area extends to TPM across the whole organisation, and the number of pillars rises to eight, adding: quality maintenance · a way of working for the administrative departments that is alive to production efficiency (TPM in the office) · health, safety and the environment within the plant.
The preparation phase
The preparation phase runs from step 1 to step 6 and ends at the formal opening ceremony.
Step 1: Announce top management’s decision to adopt TPM
The announcement of management’s decision can be made through whatever forms of communication are already in use inside the company — meetings, notice boards, internal books and magazines.
Step 2: Educate and invite participation
Run TPM training for employees at every level, including study visits off site, or send employees to training run by other bodies.
Step 3: Set up the TPM promotion committee and the TPM management chart
Establish working groups at every level — organisation, plant, department and small group — all of which must then be drawn up into a chart for managing TPM activity.
Step 4: Set the TPM philosophy, policy and targets
The philosophy, policy and targets can be set by benchmarking against comparable industry, or set for yourselves by considering your present circumstances.
Step 5: Draw up the TPM master plan
This means balancing the targets, in terms of how long the work will take, against the eight pillars of TPM.
Step 6: Hold the formal TPM opening ceremony
Hold the opening ceremony, inviting customers, group companies or partner companies to attend.
The implementation phase
The implementation phase begins immediately after the opening ceremony. It consists of step 7, raising production efficiency along pillars 1 to 4, and step 8.
Step 7.1: Individual improvement (pillar 1)
Carried out by task teams and by the maintenance small-group teams.
Step 7.2: Autonomous maintenance (pillar 2)
Carry out the seven steps of autonomous maintenance, and hold the competition between the autonomous maintenance groups.
Step 7.3: Planned maintenance (pillar 3)
Being ready for failure, preventing failure, and developing and improving the machines.
Step 7.4: Developing operating and maintenance skill (pillar 4)
Provide for the development of operating and maintenance skills — basic maintenance, adjustment, and checking equipment after it has run.
Step 8: Maintenance considered from the design stage (pillar 5)
Develop new products that are better, faster, easy to produce and easy to maintain.
The improvement and consolidation phase
The improvement and consolidation phase extends TPM from the production area out across the whole organisation, along pillars 6 to 8, ending in seeking certification.
Step 9: Establish quality maintenance (pillar 6)
Create production conditions that will not give rise to defects, and maintain in order to hold those conditions.
Step 10: Establish TPM in the office (pillar 7)
Support the production departments’ activity, and improve the efficiency of the administrative work bearing on the machines and equipment.
Step 11: Establish health, safety and the plant environment (pillar 8)
Campaign for “zero accidents” and “zero pollution”.
Step 12: Bring everything to completion and raise the level of TPM
Seek certification from the institutes, and set the targets higher.