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Implementing TPM

Release Date: 2020/08/01
ISBN: 9781000162073
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This book provides an understanding of the complexity and comprehensiveness of the total productive maintenance (TPM) process. It supplements works by Japanese authors with guidance and detail on how the TPM process relates to North American plants or facilities.

Table of Contents

  1. Cover
  2. Half Title
  3. Title Page
  4. Copyright Page
  5. Table of Contents
  6. Publisher’s Message
  7. Preface
  8. 1 Introduction
    1. What Is Total Productive Maintenance?
    2. Is TPM Right for Your Plant?
    3. What Else Is in This Book?
  9. 2 Success of TPM in Japan—JIPM
    1. Japan Institute of Plant Maintenance Background
    2. North American Maintenance Improvement Organizations
    3. JIPM Awards
    4. 1991 TPM World Congress
    5. North American TPM
  10. 3 Preparatory Stage of TPM
    1. Step One: Launch an Educational Campaign to Introduce TPM to the Organization
    2. Step Two: Create an Organizational Structure to Promote TPM
    3. Step Three: Announce Upper Management’s Decision to Introduce TPM
    4. Step Four: Establish Basic TPM Policies and Goals
    5. Step Five: Form a Master Plan for Implementing TPM
    6. Step Six: Kick Off TPM
  11. 4 Implementation Stage of TPM
    1. Step Seven: Improve the Effectiveness of Each Critical Piece of Equipment
    2. The Importance of Small Groups
    3. Step Eight: Set Up and Implement Autonomous Maintenance
    4. Step Nine: Establish a Planned Maintenance System in the Maintenance Department
    5. Step Ten: Provide Training to Improve Operator and Maintenance Skills
    6. Step Eleven: Develop an Early Equipment Management Program
    7. Step Twelve: Perfect TPM Implementation and Raise TPM Levels
  12. 5 The Seven Levels of Autonomous Maintenance
    1. Initial Cleaning
    2. Preventive Cleaning Measures
    3. Development of Cleaning and Lubrication Standards
    4. General Inspection
    5. Autonomous Inspection
    6. Process Discipline
    7. Independent Autonomous Maintenance
  13. 6 Unions and TPM
    1. What Can TPM Do for the Unions?
    2. What Can the Unions Do for TPM?
    3. How to Get Union Involvement in the Process
  14. 7 Measuring Overall Equipment Effectiveness
    1. Availability
    2. Performance Efficiency
    3. Quality Rate
    4. OEE Calculation for a Single Machine
    5. Using the Overall Plant OEE Measurable
    6. Calculating a Line or Process OEE Number
    7. Accounting for Quality Losses
    8. Plant OEE Calculation
    9. Corporate or Division OEE Measures
    10. Showing the Results of OEE
    11. The Power of OEE
  15. 8 TPM and Theory of Constraints / Continuous Flow Manufacturing
    1. What Is Continuous Flow Manufacturing?
    2. What Is the Theory of Constraints?
    3. Theory of Constraints/Continuous Flow Manufacturing and the Process Industry
    4. How to Correlate Theory of Constraints with TPM
  16. 9 TPM and Benchmarking
    1. Finding a Benchmarking Partner
    2. Choosing the Benchmarking Team
    3. The Benefit of In-Depth Observation
    4. Cross-Industry Networking Groups
    5. Quantitative and Qualitative Benchmarking
  17. 10 Successful TPM Companies
    1. E.I. DuPont
    2. Magnavox
    3. Texas Instruments
    4. Kodak
    5. Future of TPM in North America
  18. Appendix: Typical TPM Master Plan
    1. Process Milestones
    2. Year-by-Year TPM Goals and Objectives
    3. Year One Goals
    4. Year Two Goals
    5. Year Three Goals
    6. Year Four Goals
    7. Year Five Goals
  19. About the Authors
  20. Index
18.221.141.44