Preparatory Stage

Step 1: Announcement of TPM

• Proper understanding, commitment and active involvement of the top management in needed for TPM implementation.
• Top management needs to create an environment that will support the introduction of TPM.
• Without the support of management, skepticism and resistance will kill the initiative.
• Top management should have awareness programs, after which announcement is made to all.
• Publish it in the house magazine and put it in the notice board.
  Send a letter to all concerned individuals if required.

Step 2: Launch a formal education program

• This program will inform and educate everyone in the organization about TPM activities, benefits, and the importance of contribution from everyone.
• Training is to be done based on the need. Some need intensive training and some just an awareness.
• Take people who matters to places where TPM already successfully implemented.

Step 3: Create an organizational support structure

• This group will promote and sustain TPM activities once they begin.
• This group needs to include members from every level of the organization from management to the shop floor.
• This structure will promote communication and will guarantee everyone is working toward the same goals.

Step 4: Establish basic TPM policies, working systems and quantifiable goals

• Analyze the existing conditions and set goals that are SMART: Specific, Measurable, Attainable, Realistic, and Time-based.

Step 5: Outline a detailed Master Deployment Plan

• This step is an implementation leading to institutionalizing wherein TPM becomes an organizational culture.
• This plan will identify what resources will be needed and when for training, equipment restoration and improvements, maintenance management systems and new technologies.
• Achieving PM award is the proof of reaching a satisfactory level.

Introduction Stage

Step 6: TPM kick-off

• Implementation will begin at this stage.
• This is a ceremony and we should invite all.
• Suppliers as they should know that we want quality supply from them.
• Related companies and affiliated companies who can be our customers, sisters concerns etc.
• Some may learn from us and some can help us and customers will get the communication from us that we care for quality output.

Implementation Stage

In this stage 8 activities are carried which are called eight pillars in the development of TPM activity:
  • 4 Activities are for establishing the system for production efficiency
 5 S
 Autonomous Maintenance
 Individual Improvement
 Preventive Maintenance
  • 1 Activity for initial control system of new products and equipment "Quality Maintenance"
  • 1 Activity for improving the efficiency of administration "Office TPM "
  • 1 Activity for Training & Development
  • 1 Activity for control of safety, sanitation as working environment.

Step 7: Improve effectiveness of each piece of equipment

• Project Teams will analyze each piece of equipment and make the necessary improvements.

Step 8: Develop an autonomous maintenance program for operators

• Operators routine cleaning and inspection will help stabilize conditions and stop accelerated deterioration.

Step 9: Develop a planned or preventive maintenance program

• Create a schedule for preventive maintenance on each piece of equipment.

Step 10: Conduct training to improve operation and maintenance skills

• Maintenance department will take on the role of teachers and guides to provide training, advice, and equipment information to the teams.

Step 11: Develop an early equipment management program

• Apply preventive maintenance principles during the design process of equipment.

Institutionalizing Stage

Step 12: Continuous Improvement

• As in any Lean initiative the organization needs to develop a continuous improvement mindset.
• By all there activities one would has reached maturity stage.
• Now is the time for applying for PM award.
• Also think of challenging level to which you can take this movement.