TPM Framework — 8 Pillars of Total Productive Maintenance

The JIPM Framework — 全員参加の生産保全

Based on the Japan Institute of Plant Maintenance (JIPM) methodology and Nakajima's TPM Development Program. Total involvement of operators, maintainers, and engineers toward zero losses.

Autonomous Maintenance Operator-driven care, cleaning, inspection, basic repairs

12.5%

Planned Maintenance PM scheduling, spare parts strategy, reliability targets

12.5%

Quality Maintenance Zero defects, process capability analysis, poka-yoke

12.5%

Focused Improvement Kobetsu Kaizen, loss elimination, PDCA cycles

12.5%

Early Equipment Management Design for maintainability, LCC analysis, commissioning

12.5%

Training & Education Skill matrix, multi-skilling programs, one-point lessons

12.5%

Safety, Health & Environment Zero accidents, risk assessment, environmental compliance

12.5%

TPM in Administration Office efficiency, information flow, support processes

12.5%

Main pillars (80% of score)

Foundation (20%)

All pillars: equal

Maturity Scale (1.0 – 5.0)

Innocent

< 1.8

›

Aware

1.8 - 2.6

›

Developing

2.6 - 3.4

›

TARGET

Competent

3.4 - 4.2

›

Excellent

≥ 4.2

The 6 Big Losses TPM Eliminates

OEE Loss Categories TPM target: ZERO

Equipment failures (breakdowns)

✗

ELIMINATED

Setup & adjustment losses

✗

ELIMINATED

Idling & minor stops

✗

ELIMINATED

Reduced speed

✗

ELIMINATED

Process defects

✗

ELIMINATED

Reduced yield

✗

ELIMINATED

Losses

Zero Losses Philosophy

85%+

World-Class

OEE Performance Zones

<65% Unacceptable

65-75% Typical

75-85% Good

>85% World-Class

OEE = Availability x Performance x Quality

The Business Case

World-Class OEE 85%+ world-class OEE target from typical 60% baseline

Zero Philosophy Zero zero breakdowns, zero defects, zero accidents

Downtime Reduction 40-60% reduction in unplanned downtime through pillar activities

Losses Eliminated 6 losses the big losses eliminated through 8 TPM pillars

OEE improvement: 60% to 85%+ world-class 60% → 85%+

Breakdown reduction over 3 years -90%

Quality defects reduced through quality maintenance -75%

Operator engagement & ownership culture Top quartile