A Brief History of Total Productive Maintenance
Long time after first industrial revolution
(initiated in Great Britain, in the mid of 18th century, in between
1820 to 1840), the manufacturing process based industries from Europe, United
States, Germany Russia and most of the other countries realized that the
continuous manufacturing processes required for mass production are completely
dependent on a synchronous interaction of human and machine. It is in did,
needless to mention that with the evaluation and advancement of automation,
equipment dependency also increases. Overall productivity thus, is a result of
high performing machine operated by a skilled operator.
Figure 1. A
Roberts loom in a weaving shed in 1835. Textiles were the leading industry of
the Industrial Revolution, and mechanized factories, powered by a central water
wheel or steam engine. (Picture collected from Wikipedia link : https://en.wikipedia.org/wiki/Industrial_Revolution)
After Second World War
was concluded in Sep’1945, Japan also focused to turn around their economy by
strengthening business networks around the world. They were supported by United
States and a good amount of knowledge exchange between Japan and US was visible
at that period. Many industrial experts, statistician s and subject matter
experts travelled form US to Japan and Japan with its unique managerial
expertise adopted all the concepts and developed unique Japanese management
systems, most popular among are Total Quality Management and Total Productive
Maintenance.
When the concepts of
maintenance first entered in Japan from United States approximately around 1950
-51 it was used to mean preventive maintenance. Earlier the concept of
breakdown maintenance (i.e. repairing the machine after breakdown occurs) was
quite popular. In between 1950 s to till 1960 s various other aspects of
maintenance were also introduced in Japan, namely Productive Maintenance (PM),
Corrective Maintenance (CM), Maintenance Prevention (MP), Reliability
Engineering (RE), Maintainability Engineering etc. along with which idea of
Preventive Maintenance form Unitd States became quite popular among Japanese
manufacturing experts.
Nippondenso was the first company to introduce plant wide preventive maintenance
in 1960. Preventive Maintenance is the concept wherein, operators produced
products using machines and the maintenance group was dedicated with work of
maintaining those machines. But with the automation of Nippondenso, maintenance
became a problem as more maintenance personnel were required. So the management
decided that the routine maintenance of equipment would be carried out by the
operators themselves. Thus modern maintenance concepts were brought in to
existence by modifying the American traditional idea of Preventive Maintenance combining it with
unique Japanese perspective and then tailoring it to the Japanese ways of
management.
From 1960 s through
1970s concepts of traditional maintenance underwent numerous modifications which
added value and gradually the concepts of Total Productive Maintenance came
into picture.
Nippondenso which
already followed preventive maintenance also added Autonomous Maintenance which
was taken-up by production operators.
The maintenance personnel’s went in the
equipment modification for improving machine reliability, thus paving the ways
to the concepts of Maintenance
Prevention. Preventive Maintenance
along with Maintenance Prevention
and Maintainability Improvement brought
Productive Maintenance
principals. The target of Productive Maintenance now was to
deliver plant and equipment effectiveness to achieve optimum life cycle cost of
machineries. Concepts of Productive maintenance combining with total employee
involvement, management focus towards effective production process and management
structure was framed as TPM or Total productive maintenance. Nippondenso Co.
Ltd. , a TOYOTA group company, because of it’s unique initiatives in the path
of enriching TPM, was awarded the distinguished plant prize for developing and
implementing TPM, by the Japan
Institute of Plant Engineers ( JIPE ), for the 1971 fiscal year. Being
able to recognize the value of TPM
practices for the coming era of automation since 1970 s to till date
Japan Institute of Plant Engineers and Japan Institute of Plant Maintenance are
promoting the concepts of TPM. The TPM Awards are promoted by the Japan
Institute of Plant Maintenance (JIPM) and approximately 2,000 plants have
received TPM Awards both in Japan and outside since the inception of the
awards.
Some of the
remarkable events are listed below (Following details are taken from the reference Link: https://www.jipm.or.jp/en/company/history/ ) :
1961
|
The Japan
Management Association (JMA) establishes a Plant Maintenance Committee.
|
1964
|
A system for
awarding PM Awards is established.
|
1969
|
The Plant
Maintenance Department is dissolved and the Japan Institute of Plant
Engineers is established.
|
1971
|
The concept of
plant maintenance with total participation (Total Productive Maintenance) is
proclaimed.
|
1981
|
The Japan
Institute of Plant Maintenance is launched, following approval from the
Ministry of International Trade and Industry as charitable corporation.
|
1989
|
|
1990
|
The Japan
Association of Maintenance and Service Contractors is launched.
|
2005
|
JIPM Solutions
company limited is separated and transferred from JIPM as a profit-seeking
corporation.
|
2012
|
JIPM was
approved as a public interest incorporated association by the prime minister.
|
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