Total Productive Maintenance, an original Japanese management protocol developed to alleviate production losses caused by machine breakdowns, has moved on. Through TPM, more companies now accept the concept of zero breakdowns as achievable. From the foundation of striving for zero breakdowns, world-class plants are able to run for complete shifts without the need for intervention. TPM is still pushing back the boundaries of what was thought possible. This does not mean that people are no longer needed. On the contrary, it is the ingenuity of operators, maintainers, engineers and management, working as full members of the company team, which makes such progress possible, often working as a positive ’partnership for change’.
Based on our experience of working with world-class companies, this book provides a practical guide to delivering TPM benefits within cultures where professional cynics have had years to practise their craft. Based on the proven principles of TPM, the book emphasizes the need to build on existing good practices and to win commitment by delivering results. It is based on the author’s first-hand experience of seeing TPM in Japan and then adapting those principles to suit the strategic needs of companies across four continents. It builds on Peter’s earlier book TPM the Western Way, updating the scope of applications and tools. It includes more detail on the ‘life after pilot’ as well as the application of TPM to equipment design, administration and nonmanufacturing areas. The TPM route map is updated to include the journey to zero breakdowns and beyond. It also provides a systematic structure to evolve from the classic Total Productive Maintenance towards Total Productive Manufacturing and, hence, deliver a Totally Productive Operation capable of world-leading performance.
Peter Willmott and Dennis McCarthy.