| Introduction to TPM by Seiichi Nakajima |
| “This book provides an executive and
management overview and includes case examples from several Japanese plants that have won
the prestigious PM Prize. |
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| TPM in Process Industries by Tokutoro Suzuki |
| “In this book, top consultants document
approaches in implementing TPM in process industries”. |
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| TPM for Workshop
Leaders by Kunio Shirose |
| This book gives “… practical
examples and graphics to covey the hands –on leadership issues of TPM implementation. |
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| Quality Maintenance by Seiji Tsuchiya |
| This book tell you how to “achieve
zero-defect product quality by eliminating the root causes of your equipment defects. |
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| TPM New
Implementation Program in Fabrication and Assembly
Industries by Kunio Shirose |
| “In this book, top consultants document approaches in implementing TPM
in Fabrication and Assembly industries”. |
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| Eliminating Minor
Stoppages on Automated Lines by Kikuo Suehiro |
| “More and more automated equipment is
being incorporated into production processes. Although
this trend solves certain problems, it creates others.
This is especially true when the equipment must be stopped, even briefly, to
effect the necessary repair. Equipment
improvements are actually improvements to the production process itself. This book describes a step-by-step procedure for
eliminating a certain type of problem in automated equipment – that of minor
stoppages”. |
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| TPM for Every Operator edited by The Japan Institute of Plant Maintenenace |
| “One of the basic principles of TPM is
that operators are the first line of defense against unplanned equipment downtime. Operators and others in daily contact with
equipment can use their knowledge and familiarity with operating conditions to predict and
prevent breakdowns and other equipment-related losses.
TPM for Every Operator teaches operators and team leaders the key concepts
of TPM to support companywide participation – the hallmark of the TPM approach”. |
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| Kobetsu Kaizen Manual – Focussed
Improvement |
| This manual gives the details of “KK
pillar, its aims and activities, classification of losses, 7 step methodology for
eliminating the losses, details of 16 major losses with company specific examples. Some tools such as cause & effect analysis and
why-why analysis which are used to study these losses are also discussed in this manual”. |
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| Quality Maintenance Manual |
| This manual gives the details of “QM pillar, its aims and activities,
methodology for implementation with details of various tools deployed along with specific
company examples. Some of the tools like PM
Anaysis, 3M Analysis, Plan for Quality maintenance, Poka Yoke and Kaizens for Eliminating
Defect are also described in the manual”. |
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| Poka-Yoke Book on Mistake Proofing |
| “The secret of achieving Zero Defect
Quality in Japan has been attributed to the successful application of simple Poka –
Yoke or Mistake Proofing techniques. Poka-Yoke
is a simple, yet powerful technique if the idea behind it is understood and correctly
applied by fine tuning it. This book covers
theory and actual case studies implemented in many companies”. |
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| Zero
Defect Manual for Machine Shops |
| “This manual is compiled machining
process wise; in each process, A-type, B-type and C-type defect elimination kaizen sheets
are compiled in order. Each kaizen sheet
describes, in sequence, the defect phenomenon, how it occurs, the analysis for real cause,
idea for the kaizen, how the idea is converted into an action and what is the result of
the action. This manual is aimed at providing
solution to achieve Zero defects in machine shops”. |
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Process industries have
a particularly urgent need for collaborative equipment management systems like TPM that
can absolutely guarantee safe, stable operation. Process industry plants must operate
continuously for long periods to be cost-effective. Accidents and breakdowns involving
even one piece of equipment can shut down an entire plant and endanger life and the
environment. The resulting financial losses can be devastating. In the past seven to eight
years, many process industries in Japan and the U.S. have found it profitable to build TPM
programs based on their existing preventive maintenance and quality improvement programs.
In TPM in Process lndustries top consultants from the illustrious JIPM-S (Japan Institute of
Plant Maintenance) document approaches to implementing TPM in process industries. This
book follows the format of TPM Development Program, the original TPM "bible,"
which focuses primarily on fabrication and assembly industries. JIPM-S consultants adapted
and modified the original program to suit the unique needs of process industries. This
book is a must for anyone implementing TPM in a process industry plant. The material is
focused for process environments and on equipment issues such as process loss structure
and calculation, autonomous maintenance, equipment and process improvement, and quality
maintenance. As it represents the latest thinking on TPM, any manager facing low
operator/machine ratios, managing large equipment, or coordinating extensive improvement
activities will want to read this book. Contents: An overview of TPM Maximizing production
effectiveness Focused improvement Autonomous maintenance Planned maintenance Early
management Quality maintenance Operating and maintenance skills training TPM in
administrative and support departments Building a safe, environmentally friendly system
TPM small group activities Measuring TPM effectiveness |
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This package covers the
main aspects of TPM and begins the education process that will introduce frontline workers
to this important manufacturing strategy. The enhanced Leader's Guide includes full
discussion guide notes as well as tips for addressing the issues which TPM often raises
for operators. An excellent tool for supporting your TPM training initiatives. Includes
Leader's Guide 5 copies of TPM for Every Operator Overhead transparencies TPM for Workshop
Leaders The TPM for Every Operator Learning Package is designed to give an overview of the
concepts and strategies of a companywide TPM program for operators and other plant floor
personnel. If your company is implementing a companywide TPM program to reduce
equipment-related loss, the learning group activity offered here will be most effective as
part of an initial awareness effort. It will prepare group members for participation in
actual implementation by introducing basic TPM activities and demonstrating why they are
important. It will also help group leaders address issues that can affect buy-in on the
plant floor level. Alternate agendas and exercises are provided so that you can tailor the
program to time and resource limitations in your environment. In setting up a learning
group, make sure you understand how it fits into the company's TPM initiative and with
other area or company initiatives, such as quality, autonomous work teams, or
cost-reduction activities. Work with appropriate area and plant managers to define the
purpose of this learning activity and to clarify management's goals and expectations. Then
you can organize the activity narrowly to achieve this purpose. |
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This book explains, in
an easily understandable manner, TPM procedures as they are currently implemented in the
fabrication and assembly industries, and reflects throughout the guidance, expertise, and
know-how of specialised consultants. For example, the book lists 16 major losses as
factors that impede the efficiency of fabrication and assembly. With regard to specific
improvements, the book explores programs for reducing seven major losses, such as
"cutting blade losses", using up-to-date examples. Explanations of the eight
pillars of TPM implementation, such as autonomous maintenance (Jishu-Hozen), quality
maintenance, and planned maintenance, were modified to apply specifically to TPM for
fabrication and assembly. |
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Stoppages of automated
equipment lines adversely affect productivity, cost, and lead time. Such losses make
decreasing the number of stoppages a crucial element of TPM. Kikuo Suehiro has helped
companies such as Hitachi achieve unprecedented reduction in the number of minor
stoppages. In this explicitly detailed book, he presents a scientific approach to
determining the causes of stoppages and the actions that can be taken to diminish their
occurance. |
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Equipment management has
a direct and substantial impact on the cost, quality, and production time of your
products. This ground-breaking book describes a systematic approach to the improvement of
equipment design and development that will greatly enhance your company's competitiveness.
Gotoh, the developer and leading proponent of maintenance prevention design techniques,
offers insight and expertise in this first book ever to approach Total Productive
Maintenance (TPM) through the design of new equipment. An introduction to the concept of
building maintenance prevention features into equipment at the design stage, the book
demonstrates the theories and ideas presented with ample case studies, illustrations, and
charts. Written for design engineers, maintenance technicians, manufacturing engineers,
and managers, the book's revolutionary concepts of equipment design and development enable
you to reduce significantly the time from new equipment design to stable operation,
achieve an effective balance between equipment maintenance, planning, and improvement,
produce more reliable equipment with lower life cycle costs. The book also analyzes five
basic conditions for factory equipment of the future: stronger R & D, greater
reliability even in advanced designs, lower life cycle costs, and greater flexibility and
maintainability. It discusses the importance of each of the five conditions to your
company's competitiveness and how to manage them through more effective equipment
development. |
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Focused equipment
improvement (FEI) is one of the pillars of TPM. This book gives shopfloor TPM teams,
including production workers, maintenance technicians, engineers, and managers, a strong
framework for further improving equipment performance. As distinguished from autonomous
maintenance, where the main goal is to restore basic conditions of cleanliness,
lubrication, and proper fastening to prevent accelerated deterioration, FEI looks at
specific losses or design weaknesses that everyone previously thought they just had to
live with. Once your TPM operator teams are progressing with their daily autonomous
maintenance activities, you will want to take the next advanced step in TPM training with
this book |
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In this large-format
implementation manual, TPM experts explain P-M Analysis methodology that makes zero losses
a reality in your TPM program. P-M Analysis is designed to help your TPM teams analyze and
eliminate chronic losses problems that have been neglected or unresolved in the past.
Chronic quality defects and other chronic losses are hard to eradicate, because they
typically have multiple, interrelated causes that vary with every occurrence. Common
improvement strategies, like cause-and-effect analysis, are usually ineffective in dealing
with such complex problems. P-M Analysis was specially developed to overcome the
weaknesses of traditional methods. It offers a rigorous 8-step method for ensuring that
all possible factors are identified and investigated. Through P-M Analysis, teams really
get in touch with their equipment. Its unique skill-building process improves
technological know-how while delivering solutions to persistent problems. The first four
steps of this rigorous 8-step program help teams isol ate and understand the root causes
of defects and failures within main equipment mechanisms and peripheral systems. The final
four steps provide a systematic approach for effectively controlling those causes. A
critical concept in P-M Analysis is physical analysis -- a way of thinking about how
defects and failures are generated that forces us to look at the physical principles
involved and to quantify the changes in the relationship between the equipment mechanisms
and product parts involved. When a proper physical analysis is carried out, teams are far
less likely to overlook important factors or to waste time pursuing unrelated ones.
Although not a cure-all, P-M Analysis properly implemented has reduced chronic losses to
zero and raised technological expertise in many manufacturing environments. This profusely
illustrated implementation manual provides a thorough step-by-step procedure for
implementing P-M Analysis, along with practice exercises and graded examples, and many
detailed case studies. It is an unparalleled resource for anyone with a basic knowledge of
TPM who is ready to fine-tune their loss-reduction activities. Here, finally, is a
root-cause analysis method that will help teams achieve the ultimate goal of zero losses. |
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What can your company do
to achieve zero-defect product quality? Trace defects in equipment to their root causes
and permanently eliminate them through team-based equipment management and low-cost
improvements. Learn how to integrate TPM concepts and methods in your quality program in
this easy-to-read case study of TPM, TQC, and JIT at a world-class manufacturer of optical
fiber and other electric cable and wire. Using numerous shop floor examples, the author
shows supervisors and team leaders how to manage equipment to guarantee higher quality. |
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Total Productive
Maintenance (TPM) combines the best features of productive and predictive maintenance with
innovative management strategies and total employee involvement. This collection of
foundational articles and classic implementation case studies culled from NKS Factory
Management Journal details how TPM has helped prize-winning companies in Japan achieve
remarkable results. This book is packed with information not available in English anywhere
else. It includes in-depth explorations of the approach to loss reduction and plantwide
implementation, a classic essay on the relationship between JIT and TPM by | Seiichi
Nakajima, the "Father" of TPM, and numerous detailed examples of equipment
modifications addressing specific types of loss. The material in this book originally
appeared as part of the Factory Management Notebook Series and is being offered at a
reduced price in a new easy-to-use format due to increased demand. |
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A simple very effective
way to immerse every frontline worker in Total Productive Maintenance. Total employee
involvement is the foundation of any successful TPM program. To improve production quality
and lower costs, the education and participation of all employees is essential. TPM for
Every Operator introduces frontline workers to the basics of TPM, concentrating on focused
improvement, autonomous maintenance, and safety activities. The explicit illustrations
that appear on almost every page visually reinforce such TPM principles as: eliminating
the six big losses that cause breakdowns and defects establishing a daily cleaning,
lubrication, and bolt tightening routine working with maintenance personnel to improve
equipment effectiveness and promoting equipment improvement through independent small
group activities. TPM for Every Operator is part of the Productivity Press Shopfloor
Series, condensed books for operators, team leaders, and supervisors containing
information on key manufacturing topics. This book is a companion volume to TPM Team Guide
which discusses the principles of team-based TPM activities. We express our appreciation
to the Japan Institute of Plant Maintenance, the original author and publisher, for
permitting us to publish this edition of TPM for Every Operator. |
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The benefits of advanced
manufacturing methods can't be realized until they're practiced consistently and
proficiently by your entire workforce. Here's a simple, low-cost way to get everyone on
board quickly. This small book presents the basic methodology of TPM and focuses on
hands-on activities for shopfloor teams to maximize equipment effectiveness. Feedback from
our customers indicates that this book has been used primarily by shopfloor supervisors to
lead operator teams in implementing TPM programs. For the most cost effective on-site
education, every supervisor and team leader in your operation should read this book. This
book offers an overview of the basic features of TPM as well as the implementation process
in an easy-to-follow presentation. It focuses on the important role of supervisors in
maximizing equipment effectiveness. For the most cost-effective on-site education, every
supervisor in your operation should read this book. It presents the basic methodology of
TPM in clear, accessible language and will help supervisors implement TPM improvement
activities on the shop floor. It's the best way to ensure a companywide understanding of
TPM. Contents: Causes of breakdowns and defects What is total productive maintenance?
Characteristics and goals of TPM Eliminating equipment losses Autonomous maintenance
activities in production Companywide cooperation in TPM |
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Workshop leaders play a
central role in your company's efforts to implement TPM. Once your workers have been
divided into small groups to learn the fundamentals of TPM, it is the group leader who
spearheads ongoing training and implementation activities. With quick-reading,
people-oriented practicality, this new book addresses the role of the workshop leader in
maximizing the benefits of TPM. A top TPM consultant in Japan, Kunio Shirose: Incorporates
cartoons and graphics to convey the hands-on leadership issues of TPM implementation Uses
case studies to reinforce his ideas on training and managing equipment operators in the
care of their equipment Itemizes specific activities that must be undertaken to search
out, correct, and control defects to remedy equipment shortcomings. He also addresses the
cooperative relationship necessary between maintenance and production and leaves you with
an understanding of the three imperatives for successful TPM implementation to change the
quality and functioning of the equipment, the way operators think about equipment, and the
workplace. |
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Total
Productive Maintenance (TPM) is a system so effective it's been shown to reduce breakdowns
to almost zero and increase worker productivity by as much as 150%. Since it was first
introduced in Japan by Mr. Nakajima, TPM has caused a worldwide revolution in plant
maintenance. It is now attracting the attention in the West that it deserves. Introduction
to TPM shows you the features of TPM that increase the effectiveness of JIT and automated
production systems: Activities to maximize equipment effectiveness Autonomous maintenance
by operators Systems to promote maintainability from design through retirement of
equipment Providing an executive and management overview, Nakajima's Introduction to TPM
reviews the twelve steps involved in implementing TPM over a three year period. Plus, it
provides case examples from several Japanese plants that have been awarded the prestigious
Productive Maintenance Prize. This book will help you get started right away in laying the
foundations of your own TPM program. |
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TPM involves employees
companywide in preventing equipment abnormalities and breakdowns. The first line of
defense: quipment operators-the people most familar with daily operating conditions. In
addition to regular cleaning and inspection, team-based improvement activities make
effective use of operators' hands-on knowledge. How do you organize TPM teams and keep
them vital? TPM Team Guide tells supervisors, workgroup leaders, and operators how to
develop the teamm-based skills required for sucessful TPM implementation. Geared toward
TPM projects, it describes basic elements of improvement activities for any kind of
shopfloor team. TPM Team Guide gives simple explanations of basic TPM concepts such as the
six big losses, and emphasizes the integration of TPM activities with production
management. Chapters describe the team-based improvement process step by step, from goal
to standardization of the improved operations. Team leaders will learn how to hold
effective meetings and deal with the human issues that stand in the way of success. The
tools for team problem solving and the steps for preparing a good presentation of results
are detailed here as well. Written in simple language, with abundant illustrations and
cartoon examples, this book makes TPM activities understandable to everyone in the
company. Frontline supervisors, operators, facilitators, and trainers in manufacturing
companies will want to use this practical guide to improve company performance and build a
satisfying workplace for employees. |
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This insightful book
demonstrates the value of TPM in the factory through a case study of Nachi-Fujikoshi, a PM
Prizewinning manufacturer of industrial precision parts that successfully adopted TPM and
continues to reap its remarkable benefits. The implementation of TPM at Nachi-Fujikoshi
resulted in: A rise in the manufacturing profit ratio of 5.3 points A drop in financial
loss due to line stoppage to less that one-tenth its pre-TPM level A reduction in the
number of monthly breakdowns from 4106 to 28 for 7,000 units This book examines Nachi
Fujikoshi's training program an the on-going role of all employees in TPM, from the
machine operator and design engineer to the plant manager. With over 130 helpful
illustrations, it recounts in detail how the company used techniq ues such as maintenance
training for operators, group activities to improve existing equipment, an maintenance
prevention methods at the machine design stage to remedy problems such as a high rate of
machine failure and variable machine cycle times. You'll find this a tremendously useful
addition to your TPM library. |
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When your
operators are positively and energetically involved in the maintenance of their own
equipment, when they are thoroughly familiar with it and treat it as their own, then TPM
leads to soaring productivity. Our newest operator book teaches specific autonomous
maintenance activities. For operators, supervisors, team leaders, and TPM coordinators,
this book provides useful guidance and case study examples for autonomous maintenance.
Activity boards, one-point lessons, photos, cartoons, and actual examples of
implementation demonstrate the huge benefits of developing informed, motivated operators
who take ownership of and improve their equipment. |
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Maintenance has a far
greater impact on corporate profitability than most managers are willing to consider, much
less admit. And, as the competitive environment in the world continues to increase the
pace, no company can ignore the advantages of Total Productive Maintenance. The author
explains how TPM is becoming an essential element of world-class manufacturing by
providing optimum maintenance policies and practices, and shows how TPM can be implemented
by modifying many of the standard techniques and programs currently used in the United
States. Table of Contents The History and Impact of TPM. Determining the Goals of TPM.
Pre-TPM Activities. Developing the Long-Range Plan and Convincing the Corporation.
Equipment Reliability. Maintenance Inventory Controls. Improving Maintenance
Effectiveness. Maintenance Automation. Training for C.A.T.'s. Total Asset Management.
Team-Based Maintenance. Measuring the Program Results. The Future of Maintenance. Index. |
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John D Campbell 1995 1
Edn USD 35 |
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Yoshikazi Takahashi 1990
1 Edn USD 20 |
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Shizuo Senju
1992 1 Edn USD 12 |
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TPM Kick-Off Ceremony
March 19th 2001,
J.K.Paper Mills
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Godrej Sara Lee Ltd.
TPM Kick-Off Ceremony
March 3rd 2001
|
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Hinoday
TPM Kick-Off Ceremony
May 22nd 2001
|
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4th Anniversary TPM Club India & 1st
TPM Conference
March 16-17th 2001: Chennai
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ViKram Cements
Final audit for TPM consistency Awards
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