Page 82 - TPM A Route to World-Class Performance

Techniques to deliver the TPM principles 63

measurement
condition
problem prevention
The present condition and future asset care requirements for the plant and
equipment are first established and then developed through the measurement
cycle, which sets the present and future levels of overall equipment
effectiveness. Finally, the improvement cycle carries the process forward to
the best of best and on to world class through a continuous improvement
‘habit’ (this concept is fully developed in Chapters 5 and 6).
Figure 4.1 shows the application of Nakajima’s principles to the three-
cycle improvement plan. Figure 4.2 shows the driving force behind Japanese
TPM, and Figure 4.3 shows the approach pioneered by the Japanese Institute
of Plant Maintenance.

Measurement Condition Problem prevention
cycle cycle cycle
1 Continuous improvement in
OEE J - J
2 Set up planned, preventive
maintenance asset care J J -
3 Establish operator asset care J J J
4 Continuous skill development J J J
5 Early equipment management J - J

Figure 4.1 Relationship between five pillars (Nakajima) and three-cycle
TPM improvement plan

Goal: economic world domination via:
- flexibility
- right products
- right time
- right quality
- right price
Trouble-free: zero defects
zero equipment failures
zero accidents
Stockless: no buffer stocks
no WIP
All equals: total waste elimination
TPM viewed as an essential pillar for equipment reliability and product repeatability through
people and not the systems alone

Figure 4.2 Essence of Japanese TPM