12 Steps of TPM Implementation

Introduction-TPM Implementation stages

Step 1: The top person's declaration of the resolve to introduce TPM

The declaration is made in an internal TPM lecture meeting, and should be printed in an internal bulletin or newsletter.

Step 2: TPM introduction education and campaign

Managerial staff: Staff of the same echelon are scheduled together for training

General employees: Slide-show meetings

Step 3: Formation of TPM promotion organizations and formal organizational models

Committees, specialized subcommittees, promotion secretariat

Formal organization models

Step 4: Setting of basic TPM principles and targets

Benchmarks and targets; prediction of effects

Step 5: Preparation of a master plan for implementing TPM

From preparation for introduction to undergoing examinations.

Start of introduction

Step 6: Kickoff of TPM

Customers, affiliated companies, and cooperative companies are invited

Introduction-execution stage

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

Pursuit of improvement of efficiency in the production department.

7.1: Kobetsu-Kaizen

Project-team activities and workshop small-group activities

7.2: Jishu-Hozen

Step method, diagnosis, and approval certificates

7.3: Planned maintenance

Corrective maintenance, periodic maintenance, predictive maintenance

7.4: Operation/maintenance skill development

Collective education of leaders & education concerning transmission of

education to members

Introduction-execution stage

Step 8: Establishment of initial phase management systems for new products & new

equipment Development of easy-to-manufacture products and easy-to-use equipment

Step 9: Establishment of quality maintenance systems

Creation of conditions in which defects do not occur, and the maintenance/management

of those conditions.

Step 10: Creation of systems for improvement of the efficiency of administrative/supervisory sectors .

Production support, improvement of the efficiency of related sectors, and improvement

of efficiency of equipment.

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

Creation of systems for zero accidents and zero pollution cases

Establishment stage

Step 12: Complete implementation of TPM and level improvement. Undergoing examinations for the receipt of PM awards; Setting sights on higher targets