Problems of TPM (2000,Sep-4w)

TPM is the abbreviation of Total Productive Maintenance. The main aim of TPM is to reduce machine failures. In order to achieve this purpose, involvement of machine operators is a vital factor. Following the TPM installation program, a company will take TPM prize. TPM prize is a kind of certifications. �@ Generally, factories having TPM prize have a lot of checklists for checking conditions of machines. Generally every morning operators do check machines in their charge. This system is based on the concept that an operator should do his or her work by his or her own responsibility. But often I found situations that workers did not check by checklists. It can be easily detected by only checking past recorded checklists. It showed managers do not monitor checklists in the name of self-motivation. But I think it is not self-motivation. It is let-alone way of management. No communication between them in a work site. No positive participation of workers is anticipated. What are causes of the problem? I think a main cause is lack of good management, and no leadership in management, therefore, no understanding by operators. Another main cause is that managers tend to pay attentions to get TPM prize, following assessors advices. Making a lot of checklists and forcing operators to use them are easy way to get their TPM prize. Sub-optimizations. Very similar to ISO9000 certifications.. A company got TPM prize. The president, then as the next program, he had a plan to attack ISO9000, but seeing the heavy documentation of TPM, he finally gave up the plan, hearing that ISO 9000 also requires heave documentation. �@ If you read a guidebook on TPM, you will find a matrix, which shows inputs and outputs of a work. Input consists of four Ms: those are Man, Machine, Material and Method. And main outputs are Quality, Delivery and Cost. One of theoretical defects of TPM is that it includes Cost in output. Cost is the monetary value of inputs. Therefore Cost is the monetary summary of 4Ms. 4Ms have different units each, and you cannot make adding them immediately to get total value of inputs. Then each 4Ms is once changed to monetary unit and adding them, you can get total value of inputs. That is Cost, not output. Cost is something sacrificed to get output. Cost is input to make output (quality, delivery). Very clear!