Friday, 5 January 2018

Eight Pillars of TPM

Eight Pillars of TPM: Application of Practical Methods to Increase Productivity in the Work Area.

TPM or Total Productive Maintenance has 3 main targets:

  1. To maintain zero product defect (no defective product).

  2. Zero equipment unplanned failures (no failure or damage to machines not detect before).

  3. No accident in the work area(Zero accident)


Eight Pillars of TPM

These targets can be achieve by performing a Gap Analysis of historical records of defective products, engine failures and accidents that have occur before. Gap Analysis can be done with fishbone diagram, why why analysis , or PM analysis. Once a clear understanding is obtain, plan an investigation to find a decrease in engine performance. This stage is call " Initial Cleaning ".

The Seven Waste


TPM is also useful to identify seven losses or seven waste (waste) on the machine, namely:

  1. Setup adjustment time

  2. Initial adjustment time

  3. Machine damage time (equipment breakdown time)

  4. Idle machine

  5. Speed ​​(cycle time) losses (decreas speed)

  6. Start-up quality losses (decrease start-up quality)

  7. In-process quality losses

The seven waste in this manufacturing process must be eliminate, it can be by applying TPM in Kaizen project . Elimination of the seven waste is an application of three outlines of TPM pillars, which include:

  • The Efficient Equipment Utilization

  • To Efficient Worker Utilization

  • Efficient Material & Energy Utilization

Of the three outlines, eight pillars are develop that support the overall implementation of TPM. These eight pillars include:

  1. Focus improvement (Kobetsu Kaizen): make sustainable improvements no matter how small the improvement is.

  2. Plan Maintenance: focus increases availability of machines and equipment and reduces engine damage.

  3. Education and Training: forming employee formation with skill and mastering technique to perform autonomous maintenance.

  4. Autonomous Maintenance (Jishu Hozen): means to take care of the machine use. There are seven steps and activities perform on Jisshu Hozen.

  5. Quality Maintenance (Hinshitsu Hozen): quality maintenance is a machine setting that minimizes the possibility of recurring defects. This is done to ensure the achievement of the target zero defect.

  6. Office TPM: how to make efficient office activities and eliminate possible losses.

  7. Safety, Hygene & Environment (SHE): is an activity to create a safe and healthy work area, which is very unlikely to happen. Find and improve accident prone areas to ensure safety while maintaining environmental health.

  8. Tools Management, to increase equipment availability by reducing tools resetting time to reduce equipment maintenance costs and extend equipment life.

TPM Success Size


The performance measurement tool that is consider to be most consistent with Lean Manufacturing and TPM is OEE (overall equipment effectiveness). OEE measurements are use to determine the potential improvements that can be made on a device or machine. Consistent application of improvement techniques such as TPM will significantly reduce losses and positively impact the performance of a device or machine that operates daily.

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