TPM and JIT are the best partners

Nippon Denso (currently DENSO), a member of the Toyota Group, was the first company in Japan to implement TPM and won the PM Award. Since then, TPM has spread across the entire Toyota Group and its affiliates, remaining a core pillar of their operations even now.

Toyota Group companies have established a lean production system and a solid management foundation by implementing Just-In-Time (JIT), a core element of the Toyota Production System (TPS). The Toyota Production System (TPS) consists of two core components: JIT production and Autonomation.

JIT, represented by the Kanban method, essentially means producing exactly what is needed, when needed, in the required amount to reach zero inventory. To fully establish JIT, it is essential to fulfill the following prerequisites:

• Zero sudden downtime: No breakdowns or minor stops on production equipment or lines.

• Minimize setup and adjustment time and ensure the Zero defects.

As JIT-driven plants move toward automated and unmanned line production, meeting these prerequisites becomes even more critical.

The goal of TPM is to achieve Zero for the 16 major losses hidden in the production systems. It strives for zero loss through a dual approach: 'reducing' existing losses, such as breakdown and defect losses that hinder production efficiency, and 'preventing' them from happening.

In short, TPM is an activity that satisfies the prerequisites for establishing JIT production. JIT can only be truly achieved when built upon the strength of TPM, making them the 'best partners' in manufacturing.

There is a strong link between TPM and JIT, and their combined efforts will create great results. However a simultaneous rollout would be overwhelming for the organization. Therefore, we recommend starting with TPM to build a solid foundation for JIT.

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