What is Total Productive Maintenance and the 8 Pillars of TPM are described in this video?
The history, the 6 big losses, and the type of maintenance are covered, too.
This video aims to be a complete TPM tutorial to learn how to implement Total Productive Maintenance by knowing all the basics and practical tips.
This video is made in collaboration with “Lean Community”
0. Intro (0:00)
1. What is Total Productive Maintenance (1:05)
2. History of TPM (2:08)
3. The 6 Big Losses (4:21)
4. The 8 Pillars of TPM (7:16)
5. TPM vs TQM (9:06)
6. Types of Maintenance (10:26)
7. The 9 Steps to Implement Autonomous Maintenance (12:23)
8. Practical Tips for TPM (15:55)
9. Conclusion (17:08)
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✏️ Here is the transcript of the video (summary)
This video has the ambition to become the definitive guide to know and implement the total productive maintenance also known as TPM.
The tutorial will be divided into chapters and in the description, you will find documents and checklists to download to have a written reference and to be guided in the implementation of the TPM step by step.
In particular, the following topics will be discussed:
What is the TPM and why it matters.
The history of the TPM.
The 6 big losses.
The 8 pillars of the TPM.
TQM vs TPM.
The different types of maintenance.
The 9 steps to implement autonomous maintenance.
Practical Tips for TPM.
▶ Chapter 1 – What is TPM and why it matters.
The purpose of the TPM is to have zero unscheduled downtime.
To achieve this, the TPM aims to have only planned downtime, for example for preventive maintenance.
The key to TPM success is to perform preventative maintenance effectively and efficiently.
▶ Chapter 2 – The history of the TPM
The TPM is a methodology born in Japan.
After the Second World War, the Japanese industry was devastated and the industrial leaders, to start again, began to adopt the American philosophies of quality management and quality control.
It is history that Dr. Deming made many trips to Japan to teach total quality management.
▶ Chapter 3 – The 6 big losses
It should now be clear to you that one of the purposes of the TPM is to make plants more efficient.
By having more efficient systems, you can work more peacefully and help increase company profits.
Making plants more efficient means eliminating the losses that reduce efficiency in general.
For machinery, losses are classified into six categories:
1. Equipment Failure
2. Setup and Adjustments
3. Idling and Minor Stops
4. Reduced Speed
5. Process Defect
6. Startup losses
▶ Chapter 4 – The 8 Pillars of TPM
Pillar 1 – Autonomous Maintenance.
Operators who use all of their senses to help identify causes for losses
Pillar 2 – Focused Improvement
A scientific approach to problem-solving to eliminate losses from the factory
Pillar 3 – Planned Maintenance
Professional maintenance activities performed by trained mechanics and engineers
Pillar 4 – Education and Training
Support for continuous improvement of knowledge of all workers and management
Pillar 5 – Early Management
Scientific introduction of equipment and design concepts that eliminate losses and make it easier to make defect-free production efficiently.
Pillar 6 – Quality Maintenance
A scientific and statistical approach to identifying defects and eliminating the cause of them
Pillar 7 – Safety, Health and Environment
A scientific approach to solutions that will improve the Safety, Health and Environment.
Pillar 8 – Office TPM
Using TPM tools to improve all the support aspects of a manufacturing plant including production scheduling, materials management and information flow.
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