Top Three Reasons why TPM (Total Productive Maintenance) Initiatives Fail

[handsofman88]

Re: Share your top three reasons why TPM initiatives fail

Ok, having worked in several large automotive plants in Indonesia (Japanese joint-ventures) I had an opportunity to work with several senior level trainers of TPM. We had a few discussions about why initiatives like TPM / 5S were so difficult to implement in Australia (other western countries) ....their top three reasons why TPM failed were:
Discipline
Discipline
Discipline

After a few more discussions they opened up a bit more and told me that in their organisations
TOP management were committed to TPM & established clear goals & targets to be achieved
TPM implementations were actively monitored by senior managers & results posted internally
Employees / teams with good results were rewarded (usually by being acknowledged in front of their peers & sometimes with small gifts / certificates of appreciation etc

 

[mehmetke]

Re: Share your top three reasons why TPM initiatives fail

Summary of "Top three reasons why TPM initiatives fail";

#1. Lack of management commitment & sponsorship- %50
#2. Lack of precise implementation plan - %25
#3. Lack of training & communication - %25

in western organisations must consider:

• Discipline
• Resistance to change
• Employe dedication

Thanks all for sharing your experiences.

 

[Stijloor]

Re: Share your top three reasons why TPM initiatives fail

Summary of "Top three reasons why TPM initiatives fail";

#1. Lack of management commitment & sponsorship- %50
#2. Lack of precise implementation plan - %25
#3. Lack of training & communication - %25

in western organisations must consider:

• Discipline
• Resistance to change
• Employee dedication

Thanks all for sharing your experiences.

Can you explain why discipline, resistance to change and employee dedication would be different in western organizations? Compared to what?

Stijloor.

 

[qusys]

Re: Share your top three reasons why TPM initiatives fail

Can you explain why discipline, resistance to change and employee dedication would be different in western organizations? Compared to what?

Stijloor.

Hi Stijloor.
Probably he intended the comparison with respect to east organization and in particular japanese ones.
Probably it could be a matter of "culture". This potential issue is also dealt with in the related "literature" of TPM.

TPM pursues standardization, probably western culture are more "creative" and do not like to stay in "scheme".

This is my opinion.

regards,

 

[Stijloor]

Re: Share your top three reasons why TPM initiatives fail

Hi Stijloor.

Probably he intended the comparison with respect to east organization and in particular Japanese ones.

Probably it could be a matter of "culture". This potential issue is also dealt with in the related "literature" of TPM.

TPM pursues standardization, probably western culture are more "creative" and do not like to stay in "scheme".

This is my opinion.

regards,

Be cautious with broad generalizations. I am curious what mehmetke has to say...

Stijloor.

 

[mehmetke]

Re: Share your top three reasons why TPM initiatives fail

Last two years, we have implemented 6sigma concept mainly to improve reliability and to reduce FRR-Field Return Rate. The project mainly involved engineers; R&D, Production and Quality. DFT, DFM, DFA, DQA, Gauge R&R were succesfully implemented and at the moment targets are achieved.

The reason to start TPM was to involve the workers on the line. But the number of the worker is 4000. I am having trouble at the start up stage of TPM. Being one of the top management, fully supportive and commited

WHAT WOULD BE THE ELEMENTS OF SUCCESFUL START UP OF TPM ?

Share your experience please

Continuing from my previous comment in search of "succesful start up of TPM", TPM methodoly compared to 6-sigma is very slow, straight forward, standard... especially at the start up stage; 5S, PM, OM.

Basicly, very boring and no excitement for participants when you start with items like 5S, OM. Also having a functional organisation soo long; (cleaning crew, maintenance teams) line workers are wondering why they have to the cleaning and maintenance people are wondering why they have to teach maintenance to line workers.


As a result, ( see also "handsofman88" comments) in western organisations we must deal with below items:

• Discipline
• Resistance to change
• Employee dedication

Check the att. please.

Take care.

 

[Stijloor]

Re: Share your top three reasons why TPM initiatives fail

As a result, ( see also "handsofman88" comments) in western organisations we must deal with below items:

• Discipline
• Resistance to change
• Employee dedication

Check the att. please.

Take care.

Please quote your source.

Stijloor.

 

[mehmetke]

Re: Share your top three reasons why TPM initiatives fail

i have a new topic started titled "suggestion system". Need your support. Thks.

 

[mehmetke]

Re: Share your top three reasons why TPM initiatives fail

2 months after starting TPM programme, I realize that it would be a lot better if
the suggestion system was in place (or at least a draft)
commity members were pre-selected (or at least candidates)
training room, training setups, and TPM office were established.

 

[bpugazhendhi]

Re: Share your top three reasons why TPM initiatives fail

1. The projection that TPM is the panacea for all productivity related problems is one reason why people loose interest in it after some time. Too much hype ultimately leads to far too much disappointment!
2. TPM is not a stand-alone technique. It is a part of TQM (Total Quality Management). Forgetting this aspect is another reason for the TPM movement loosing steam in any organisation.
3. Sustained management support is essential over a long period of time - almost indefinitely. This is very often absent.