Wednesday, April 4, 2012

Total Productive Maintenance (TPM)

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A study of total productive
maintenance implementation
F. Ireland and B.G. Dale
Manchester School of Management, UMIST, Manchester, UK
Keywords Total productive maintenance, Implementation, Organizational structure
Journal of Quality in Maintenance Engineering, 2001
In 1953, 20 Japanese companies formed a Preventive Maintenance research group and, after a mission to the USA in 1962 to study equipment maintenance, the Japan Institute of Plant Engineers (JIPE) was formed in 1969.  In 1969, JIPE started working closely with the automotive component manufacturer  Nippondenso  on the issue of PM.  The company decided to allow production  operators to carry out routine maintenance. This was the beginning of TPM. Tajiri and Gotah (1992) point out that TPM concept was communicated throughout Japan, but only a small number of factories took up the initiative in early days.  It was the severe economic situation in the early 1970s that accelerated the adaptation of TPM and it was propagated by the seven-step programme developed by the Tokai Rubber Industries (Nakajima, 1989).

The seven TPM pillars  are critical to the success of TPM,
focussed improvements,
autonomous maintenance,
planned maintenance,
quality maintenance,
education and training,
early equipment maintenance, and
safety and the environment)


*Sorabh Gupta a, P.C. Tewari b, Avadhesh Kumar Sharma c
a Department of Mechanical Engineering, Haryana Engineering College, Jagadhri, Haryana, INDIA
e-mail: Sorabh_gupta123 at
b Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, Haryana, INDIA
e-mail: pctewari1 at
c Department of Mechanical Engineering, C.R.S.C.E., Murthal, Sonipat, Haryana, INDIA

The paper has good discussion about difficulties of implementing TPM.

One point that comes to my mind is that Japanese were able to implement TPM as part of the multiskilling their production operators. In many Japanese companies due to increasing automation, production workers are having surplus time and there are being developed with mutliple skills.

History and Basic Implementation Process

by Jack Roberts, Ph.D.
Jack_Roberts at

Original knol - 3176
A comment
Autonomous Maintenance Level 2 Training Program Here is a resource you may want to use and/or share with others. It is a 4 CD set (Silver CD set) that provides more detailed equipment and maintenance training material for operators as a 30 week training program. Has a maintenance newsletter per week too that can be freely distributed to all personnel in a single facility. (Written in plain English for equipment operators to easily absorb.)
Must see at and share with others. A great TPM tool to take your Autonomous Maintenance program to the next level.

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