Typical 8 pillar approach

TPM follows a unique 8 Pillar approach. Each of the pillars represents the typical functions of the company. The objective of each pillar is to improve the activities of that function ie, improve their KPI’s there by improve the company’s performance towards competitiveness. Every one contributes towards competitiveness through autonomous small group activities across the company.

The activities of each pillar are designed with a specific purpose of improving the organizational excellence. The highlights are as follows:

Individual Improvement Pillar (also called as focused improvement pillar or Kobetsu Kaizen Pillar) focuses on the losses that are essentially present in manufacturing. The activities leading to reducing machine related losses such as set up time loss, tool change time loss, minor stoppages, reduced speed etc. By adopting structured approach, the losses can be reduced drastically. Generally there is a 25 – 50% increase in OEE though the improvements carried out through the activities of this pillar.

Autonomous Maintenance Pillar (also called as Jishu Hozen Pillar) focuses on how to develop the operators into a knowledgeable persons, who can take care of his / her machine. This development is brought through a 7-step approach, with activities in each step clearly defined. The activities and results of each step are audited through a unique 3 levels approach. The success and sustainability of each of these steps are dependent on these audits. The graduation of the machines along the autonomous maintenance 7 steps can be clearly seen with the shop floor becoming cleaner, neater and an enjoyable place to work. A nicely practiced autonomous maintenance activity not only increases production but also prevents the Cost Loss that is occurring in the machines.

Planned Maintenance Pillar (also called as Keikaku Hozen Pillar) provides focus on how to make the maintenance man do a quality maintenance job. The two major activities are carried out in this pillar. The first set of activities lead to increase in the availability of the machine and second set of activities lead to reduction of cost. By implementing Planned Maintenance activities in a structure way, companies have achieved 10-15% increase in availability of the machines and reduction of maintenance cost by 30-35%. In combination with autonomous maintenance pillar, companies can achieve ZERO breakdowns across all the machines in the organization.

Quality Maintenance Pillar (also called as Hinshitshu Hozen Pillar) focuses to sustain the state of ZERO defects. The strategy is to achieve ZERO defects using the classical phenomenon solving approach and then to sustain it using the ten steps of Quality Maintenance. Achieving ZERO Internal rework, ZERO rejection, ZERO customer complaint and reduction of warranty are also very important parameters that are addressed by this pillar activity.

Education and Training Pillar is the most important pillar in TPM. It is the only pillar, which has link to all the eight pillars and other pillars that are likely to be created by the company to address the issues in certain specific areas for building its competitiveness. Topics of importance are identified by the respective pillars and are given to the E&T Pillar. The responsibilities of this pillar would then be to evaluate the knowledge and skill requirements of the individuals or team and then develop them accordingly in the best interest of the organisation.

Development Management Pillar gives the methodology on how to produce new products and new machines at a very short time and at lowest cost. The tools and techniques that are to be adopted at each step in the development of a new machine or the new product is clearly defined. Vertical start up (achievement of full production with in a very short time) can be achieved by adopting TPM and the methodologies laid down by the Development Management Pillar.

Office TPM Pillar has to support all the activities that are taking place in the company. First they have to become efficient in their own working area, second support for cost reduction in all the activities that are considered as administrative in nature and third provide with relevant data to all the departments so that actions can be taken based on the data that are provided.

Safety, Health & Environment Pillar is the most important pillar, which focuses on Safety in operations, Health of the operators including hygiene factors and Environment consciousness of a company. ZERO accidents and ZERO hazards are made as the primary concern for any company practicing TPM.

Focus of each pillar is as follows:

Focused Improvement
  • Ensures that improvements become part of everyone's activity
  • Aims to eliminate production losses and cost reduction
Autonomous Maintenance
  • Maintains basic conditions on the shop floor and in all the machines
  • Overall participation through TPM circles
Planned Maintenance
  • A logical analysis of real causes for real counter measures
  • Focuses on prevention
Quality Maintenance
  • Develops the perfect machine for perfect quality
  • Eliminates in-process defects and customer complaints
Development Management
  • Machines for high equipment effectiveness
  • Quick processes for developing new process
Education & Training Develops skills to ensure:
  • Uniformity of work practices on machines
  • Zero defects, zero breakdowns and zero accidents
  • The presence of multi-skilled employees in all departments
Safety, Health & Environment
  • Achieving zero accidents and zero health hazards at work
  • Working towards the maintenance of a zero pollution Plant and environment
Office TPM
  • Office become oriented to garner excellent support for manufacturing
  • Improves man hour efficiency in offices