TPM (Total Productive Maintenance) Fundamentals - How to Start TPM (12 Steps of TPM Implementation Program)

Just like in sports, TPM requires sufficient time for preparation before kicking off. One of the characteristics of TPM is its step-by-step approach, which is followed until the kickoff stage.

Steps 1 to 5 are the preparation stage, Step 6 is the TPM kickoff, Steps 7 to 11 are the execution (roll-out) stage, and Step 12 is the stabilization and upgrading stage.

It is crucial to understand the content and purpose of each step and set clear objectives. Mistakes in understanding these steps may result in reduced benefits that TPM can provide as originally intended.

At JMAC, we provide support to our clients through the expertise of about 100 experienced consultants who have a deep understanding of each step of TPM.

TPM Implementation Procedure

Pilot Phase

1. Top Management Commitment: The top management commits to implementing TPM.

2. Awareness Campaign: Conduct orientation sessions to create awareness about TPM.

3. Establish Basic TPM Policy: Set basic TPM policies and goals for the site.

4. Establish TPM Promotion Organization: Establish a dedicated team and initiate a pilot model led by the management.

5. Develop TPM Master Plan: Create a comprehensive plan outlining the roadmap for TPM implementation.

Rollout Phase 

6. Official Launch of TPM Program: Begin the factory/plant/company-wide implementation of the TPM program.

7. Introduce TPM Pillars: Implement eight TPM pillars to maximize production efficiency. These pillars include:

　　　7.1. Focused Improvement (Kobetsu-Kaizen)

　　　7.2. Autonomous Maintenance (Jishu-Hozen)

　　　7.3. Planned Maintenance (Keikaku-Hozen)

　　　7.4. Education & Training

8. Early Management (Product & Equipment)

9. Quality Maintenance (Quality-Hozen)

10. TPM in Administration and Support Departments (Office TPM)

11. SHE (Safety, Health and Environment)

12. Full Implementation and Upgrading: Achieve full implementation of TPM and enter the upgrading phase.

"If you have questions for the JMAC TPM Team, please reach out to us through the inquiry form at the top right!"