Issue 1, 21/12/98 CONFIDENTIAL This report is solely for the use of client personnel.No part of it may be circulated, quoted, or reproduced for distribution outside the client organisation without prior written approval from McKinsey & Company. This material was used by McKinsey & Company during an oral presentation; it is not a complete record of the discussion. 12 July 1999 Total Productive MaintenanceClientPeople system Operating system Quality system Business need Enabler Process and effect Sustainability and Continuous Improvement DeliveryReliability Minimum Lead time Lowest PossibleCost ZeroDefect Total Quality Process Autonomation J I T Element Over production Motion Waiting Inventory Rework Transportation Over processing StableEmployee Relations HumanResource Management Maximized people contribution Lean manufacturing methodology Elimination of waste Change management Work environment Organisation structure Continuous improvement culture People Workplace organisation TPM Process measurement & review Standardised operations Machine design Line design Factory design Intelligent automation Poka Yoke Performance monitoring Problem resolution Continuous flow processing Takt time Pull system Levelled production Waste PSDC Lean Transformation Model F M S S STotal Productive Maintenance (TPM) is productive maintenance carried out by all employees DefinitionTime Characteristics Attitudes Effect A brief history of maintenanceC o m p e t i t i v e n e s s A model for TPMT P M The goals of TPMTPM is not just a set of tools, it is part of an integrated approach to manufacturing. TPM recognises the key role that people play in maximising the effectiveness of machinery. operators know the equipment and its problems better than anyone maintenance and production departments are often in conflict teamwork is a powerful force in problem-solving and improvement work TPM will fail if it is implemented in a hurry, in a quest for results. To be successful, TPM requires:- top management support participative culture training phased implementation The preconditions of TPM