JIPM-TPM.Sample-Forms-Editing-2

gs Organization Chart Sub-comittee Departmental Meetings
Organization Chart
l Education and Administrative / Safety and Health
Training Indirect Departmental
ction Departmental Departmental Meeting
anager Meeting Meeting
Depart- Section Depart- Section Depart- Section
b- mental Manager mental Manager mental Manager
ction Meeting Meeting Meeting
anager Chair- Chair- Chair-
person person person
Promotion Staff Promotion Sub- Promotion Sub-
Office section Office section
Office
Manager Manager
Members Members Members

____ Subsection ____ Subsection ____ Member

Manager Manager ____ Member

____ Staff ____ Subsection ____ Member
Manager ____ Member
____ Group
Manager ____ Group

ion ____ Member Manager

____ Member ____ Promotion 3 1-3
Office

____ Promotion

Office

© JIPM

Purpose and Main Activities of the 8 Pillars of TPM / Table 3 1-4
of Roles of Each Specialized Departmental Meezting

Purpose and Main Activities of the 8 Pillars of TPM

Purpose Members Activities
* Realize zero losses of all types, * Staff
Individual * Line Leader • Understanding the 16 major losses
Improvement such as failure losses and defect • Calculating and setting goals for overall equipment efficiency, productivity
Autonomous losses * Operator
Maintenance * Demonstrate ultimate production * Line Leader and production subsidiary resources
efficiency improvement
Planned * Training of operators proficient in * Maintenance department • Implementation of PM analysis
Maintenance equipment staff • Thorough pursuit of equipment and production "as it should be"
* Protecting one's own equipment by
Quality maintenance one's self * Leader • Implementation of 7 steps
* Maintenance workers 1. Initial clean-up
Initial-Phase Control * Improving efficiency of maintenance
of Products and departments to prevent the 8 major * Quality assurance staff 2. Countermeasures for the source of problems and measures for
Equipment losses * Production engineering staff
* Line Group Manager difficult-to-access locations
Administrative * Achieve zero defects by supporting
/Indirect and maintaining equipment * Research and 3. Creation of tentative autonomous maintenance standards
conditions development staff
Education and 4. General inspection
Training * Reducing product development and * Production engineering
prototyping time staff 5. Autonomous inspection
Safety and Health
* Reducing the development, design * Maintenance staff 6. Standardization
and fabrication time of equipment
* Leaders and members of 7. All-out goals management
* Improving 1-shot start-up stability of administration/indirect
products and equipment departments • Daily measures
• Periodic maintenance
* Achieve zero function losses * Operators • Preventative maintenance
* Creation of efficient offices * Maintenance workers • Extending life-span
* Implementation of service support • Spare parts management
* Safety, health and • Failure analysis and prevention of reoccurrence
functions for production environment managers
departments and specialized committee • Verify quality characteristics standards; understand defect phenomena and
members performance
* Establishment of technical
education for operations and * Staff specializing in safety • Investigating the conditions for building in quality, unit processes and raw
maintenance workers and health materials, equipment and methods

* Achievement and support of zero • Investigating, analyzing and improving the conditions of malfunctions
failures • Setting 3M conditions; setting standard values for inspection
• Creation of standards that can be followed; trend management
* Realization of a healthy and
invigorating workplace that gives • Setting development and design goals
meaning to work
• Ease of production

• Ease of QA implementation

• Ease of use Reflect in MP design

• Ease of maintenance

• Reliability

• Investigate LCC

• Design: release drawing

Production: Identify problems in the prototype, trial run and initial-phase

mass production control stages

• Autonomous maintenance activities
1. Initial clean-up (personal space)

2. Work inventory

3. Countermeasures for problems

4. Standardization

5. Promotion of autonomous management activities of work

• Individual improvement through project activities
(1) Shortening of settlement schedule

(2) Improvement of distribution

(3) Improvement of purchasing and subcontracting

(4) Reform of production control system

• Basic process of maintenance
• Tightening nuts and bolts
• Aligning keys
• Maintenance of bearings
• Maintenance of conductive parts
• Prevention of leaks
• Maintenance of oil pressure and air pressure equipment
• Maintenance of electrical control equipment

• Measures to improve equipment safety
• Measures to improve work safety
• Improvement of work environment (noise, vibration and odors)
• Measures to prevent pollution
• Creation of healthy employees
• Promotion of invigorating activites

© JIPM

Table of Members of Sub-committee Meet

 = Departmental Meeting Chairperson ~ = Committee Chairperson { = Departmen

Department Departmental Promotion Office Manufacturing Manufacturing En

Meeting Department No. Department No. De

TPM Promotion Office Chairperson 12

Individual Improvement Sub-M Sub-M Staff  Sub-M
Departmental Meeting { Sub-M

Autonomous Maintenance SM Staff  SM Staff Gr
Departmental Meeting { Staff

Planned Maintenance Sub-M Staff    Sub
Departmental Meeting { Staf

Initial-Phase Control SM Sub-M    SM
Departmental Meeting { Sub

Quality Maintenance SM Sub-M Staff Staff
Departmental Meeting

Education and Training SM Staff Sub-M Group Manager
Departmental Meeting

Administrative/Indirect SM Sub-M  Group Manager
Departmental Meeting Sub-M Member  SM

Safety and Health SM
Departmental Meeting

5S Committee SM Sub-M Staff Group Manager

VE Committee SM Sub-M ~ SM … Sub-M
CS Committee
Staff

SM Sub-M Staff Group Manager

* SM = Section Manager Sub-M = Subsection Manager

tings Table of Members of Sub-committees
Departmental Meetings
ntal Meeting Promotion Office … = Committee Promotion Office Female

ngineering Engineering Business Research TPM Promotion
epartment Administration Department Department Office
Department
Staff Sub-M  {{
Sub-M

roup Manager Staff   {{
Member  {{
  {{
b-M  
ff and Group Manager   {{
 {{
b-M   Member
Member 
 SM Member
Member { Sub-M
 SM  SM
 { Staff { Sub-M

Leader Member

{ Sub-M Member

Staff Member ~ SM Member {{ 3 1-5
Member Sub-M … Sub-M Staff 

Staff Staff Member {{

Member ~ SM
… Sub-M

© JIPM

Committee Activity Plan / Example: 5

Activity details Year Year ____ Year
Purpose Motivate employees Implement plan
Target
BM (__._ points) Comm

1. Public education activities Posters Public relations
* Activities promotion, campaign

2. Education and training activities 5S video education
3. Promotional activities
Poster contest
Creation of various sta

4. Promotion conference Regular meeting twice a mon
* Draft of events
* Creation of progress control mechanism

5. Establishment activity

6. New conceptualization and implementation

5S Committee Committee Activity Plan / Example:
5S Committee
____ Year ____ Year ____

nned 5S activity (be certain to forward to PDCA) Support establishment activity

mittee diagnosis (__. points or greater) Support activities of __ points

newsletter (once per quarter) 5S Day

Personal space 5S campaign Filing campaign

andards Creation of guide for tentative standards and full-fledged standards

nth Regular meeting once a month

Tentative standard → evaluation → full 3 1-6
standardization

The road to 100 points
New implementation

© JIPM

Pilot Organization Model Team O

Purpose Create an example of implementing the autonomous maintenance
Teams A and B: Create steps for the utility (steam line) autonomous maintenance a
Team C: Create an example for the step to implement work efficiency impro
Team D:
Formal Organiza

Formal Organization Team A Formal Organization Team B

Team Leader Section Manager _____ Team Leader Section Manager _____ Te
Me
Members Plant Manager _____ Members Subsection Manager

Subsection Manager _____
_____
Subsection Manager
Subsection Manager _____
_____
Staff _____

Staff _____ Staff _____

Staff _____ Staff _____

Staff _____ Group Manager _____

Group Manager _____ Group Manager _____

Group Manager _____

Organization Chart Pilot Organization Model Team
Organization Chart
e activity step, and carry out horizontal implementation in circles.
activity, and carry out horizontal implementation in circles.
ovement, and carry out horizontal implementation in circles.

ation Team

Formal Organization Team C Formal Organization Team D

eam Leader Section Manager _____ Team Leader Section Manager _____

embers Subsection Manager Members Subsection Manager

_____ _____

Subsection Manager Subsection Manager
_____ _____

Subsection Manager Subsection Manager
_____ _____

Staff _____ Staff _____

Staff _____ Staff _____

Group Manager _____ Staff _____ 3 1-7

Group Manager _____

© JIPM

Pilot Model Registration (Autonomous Main

1. Installation location of model Department

Division
Operations Department

2. Model description

Equipment name Control No. Reason for selection and problem to be
overcome for each equipment

There are many machines of the same mo
and horizontal implementation is easy to ca

ntenance) Date: __/__/__ Pilotn Model Registration
Department Section (Autonomous Maintenance)
Promotion
Manager Manager Office

Section Team Line

e Purpose of activity Benchmark item

odel, To create an activity that (Set target values and record
arry out involves the operator them quantitatively)
Quantity of dispersed filings
[particles] in the machine vicinity
should be under 2.5 g/day.

* (Leave blank) → Registration code: 3 1 - 8 - (1)

© JIPM

Pilot Model Organization Registration 3 1 - 8 - (2)
(individual improvement)
Date prepared: __/__/__
Equipment Registration for Individual Improvement

Registration code:

Partially revised 3/24/87 Department Section Subsection Promotion
__th time Manager Manager Manager Office

1. Installation location of relevant machine

Division Department Section (Line name: _____)
Operations Department

2. Equipment name and control number (Control No.)
Equipment name

3. Main topic of improvement (circle number)

1. Zero failures 4. Speed losses

2. Setup and adjustment losses 5. Production defect losses

3. Minor stoppage and idling losses 6. Start-up and yield losses

4. Current problems (clearly state 7 major losses and other losses)

5. Improvement goals (quantify concretely as much as possible)

6. Predicted effect of improvement

7. Implementation schedule Month: ____ Month: ____ Month: ____
__/__
© JIPM
8. Principal persons in charge

Leader Sub-leader Member

* Registration code is set by the Promotion Office (Division)
Original: Retain at Promotion Office (in the Operations Department).
Copy: Retain at Promotion Office (at the Division).

TPM Department Promo

SectionMana

Subsection
Manager

_____ Circle _____ Circle _____ Circl

Circle Leader Group Circle Leader Group Circle Leader Group
Manager __ Manager __ Mana

Members Assistant __ Members Assistant __ Members Assis

otion Organization Chart TPM Department Promotion
Organization Chart
ager __
Department
Promotion Office ______

_____

le _____ Circle _____ Circle

p Circle Leader Group Circle Leader Group
ager __ Manager __ Manager __

stant __ Members Assistant __ Members Assistant __

3 1-9

© JIPM

TPM Circle Members 3 1 - 10
Registration/Notification of Change

Circle Leader --> Department Promotion Office

--> Department Manager Promotion Depart- Department Circle
Committee Leader
(Retention) Promotion Office Office ment Chairperson

Prepared __/__/__ Manager

TPM Circle Members Registration/Notification of Change

Department Circle Total number
___Department Name ___ Circle of members ___persons

Name

1 Circle Leader

2 Assistant Circle
Leader

3 Member

4 Member

5 Member

6 Member

7 Member

8 Member

9 Member

10 Member

11 Member

12 Member

13 Member

14 Member

© JIPM

List of Meetings 3 1 - 11

List of Meetings

Classification z Member { Observer

Position Meeting Role
PM SM SuM GM M DMC/CC DM/CPO DM/CM Frequency

Meeting

Overall Activities

(1) Executive Once/week Study/decide general issues related to
the "_______ Strategy."
meeting zz
4 times/year Study issues common to each
(2) Group department.

leaders’ zzz
meeting

(3) Group As Study issues set by and information
appropriate transmitted from higher up.
managers’

meeting zzzz

(4) Circle Once/2 Promote sharing of issues confronting
months circle leaders.
leaders’
meeting {{{ z { z

(5) Total Plant 2 times/year Inform everyone in the plant about
important items of concern to all.
Meeting zzzzz

Departmental Meeting Activities

(1) Departmental Once/month Share and study issues concerning
departmental activities and
meeting specialized departmental activities.

chairpersons’ zz zz As Study various issues to promote
meeting appropriate specialized departmental meeting

(2) Specialized activities.

departmental z

meeting's zz
meeting

Committee Activities

5S Committee zz Study various issues to promote
VE Committee
CS Committee z Once/month committee activities.

Departmental Activities

(1)Departmental zzz 1 time/week Study issues related to departmental
zz promotion.
meeting
1 time/week Transmit details of the departmental
(2) Circle meeting to the members, and study
meeting issues related to group promotion.

PM: Plant Manager
SM: Section Manager
SuM: Subsection Manager
GM: Group Manager
M: Member
DMC/CC: Departmental Meeting Chairperson / Committee Chairperson
DM/CPO: Departmental Meeting / Committee Promotion Office
DM/CM: Departmental Meeting / Committee Member

© JIPM

JIPM - TPM® 600 Forms Manual
Sample Formats for the12 Steps of TPM

4. Setting the Basic Policy and
Goals of TPM

© JIPM

4. Setting the Basic Policy and Goals of TPM

1 Setting Company-Wide Basic Policy and Goals (1) (2) Table of Members Organized to
1 Ensure Common Understanding
Understanding of External Environment
Implementation and Diagnosis of
2 Policy

Understanding of Internal Environment

Determination of Basic Policy

2 Determination of the Basic Policy and Goals of (3) (4) (5) Background to and Purpose of
the Plant 3 Introducing TPM (Plant)
4 Policy and Goals of TPM (Plant)
Understanding of External Environment (1)
(2)

Understanding of Internal Environment The Shift from DPM Activity to ZPM
5 Activity

Determination of Basic Policy (6) Solicitation Requirements for TPM
3 Determination of Activity Slogan 6 Activities Slogan

Solicitation of Slogan

Primary and Secondary Selection

Final Determination of Slogan

4 Creation of Activity Priorities and Activity Policy
Implementation Diagram

Creation of Activity Policy Implementation (7) Activity Policy Implementation
Diagram 7 Diagram
8 Goals Implementation Diagram
Creation of Goals Implementation Diagram (8)
Critical Tasks and Target Values by
Determination of Priority Items for Each (9) 9 Activity
Departmental Meeting 10 Basic Approach to Setting Targets

5 Organizing Basic Approaches to Setting Targets (10)

© JIPM

Table of Members Organized to Ensure 4 1-1
Common Understanding

Purpose
To clearly state the pursuit of TPM in basic management policies and in medium-term and long-term
management plans, to incorporate TPM targets in the annual targets, and to promote TPM as a part of
policy management and target management.
Implementation Items

• To clearly state the pursuit of TPM in basic management policy and in the medium-term and long-
term management plans.

• To clarify the desirable framework (3-5 years) at each organizational level, to set approaches,
priorities and targets for implementation (8 pillars of TPM), and to obtain the consensus of the
company.

External environment Department operations Desirable framework

Department functions Approach to implementation

Internal environment Environment of own Priority implementation items
department Targets

Members are organized in order to ensure the above common understanding. The following table is an
example of organizing members on the departmental and sectional levels.

Table of Members Organized to Ensure a Common Understanding (Example)

<Department Manager and Section Manager Levels>

Group Leader Members
No. 2 Casting Section
Machine Tools No. 1 Manufacturing Section Manager _____ Equipment Design Project
Manager _____ Manager _____
Department
A Manager _____ Production Engineering Union Chief Secretary _____
Department Project Manager
_____

Production Plant Manager _____ No. 4 Manufacturing Section No. 1 Casting Section

Engineering Manager _____ Manager _____
B
Union Assistant Secretary
Department Project Equipment Design Project _____

Manager _____ Manager _____

Assistant Plant No. 1 Manufacturing Department No. 5 Manufacturing Section Labor Project Manager
Manager _____
C Manager _____ Manager _____ _____

Equipment Design Project Quality Assurance
Manager _____ Department Project Manager
_____

TPM Leader _____ No. 2 Manufacturing Department Production Control No. 3 Manufacturing Section

Manager _____ Department Manager _____ Manager _____
D Cost Control Project Manager Planning Section Manager

_____ _____

No. 2 No. 3 Manufacturing Department Operations Department Inspection Section Manager
_____
Manufacturing Manager _____ Manager _____
E Section Manager

_____ Planning Section Manager _____ Manufacturing Department
Project Manager _____

© JIPM

Implementation and Diagnosis of Policy 4 1-2

Implementation and Diagnosis of Policy

After the new enterprise [reorganization] declaration was made (October, 19__), this company hammered out
a new corporate philosophy and a long-term management policy. These were further broken down into a
midterm management plan and a fiscal year policy, implemented as specific activity plans, and managed in
accordance with policy control mechanisms. TPM activities are positioned as important pillars for the im

Corporate philosophy __________[company name].
(_____ philosophy) A corporate world citizen reaching for high-tech and high-touch.

Long-term management policy 1. Global business activities

Midterm management plan 2. Creating a pleasant environment through technological
Issues to be dealt with by TPM innovation

Fiscal year 3. Environmental maintenance and nature conservation
(_____ period) priority policy 4. Satisfying a broad range of customers
5. Contributing to consumer lifestyles
6. Bringing out the best of each individual's existence and

capabilities

TPM promotion plan Midterm target and 8 pillars of
activities

Headquarters and operations department level Department level Section level

Target and policy Target and policy
implementation implementation

P Operations Department Targets (results to be obtained) Policy (means to achieve target)
Priority Policy Statement
1 Target item Target Priority Level P Department
value implementation achieved manager policy
(_____ philosophy) items document

(Long-term management policy) 2

Planning (__th period basic policy) (1) Promotion of Target Improvement of Passed F-1 D Department D Section
1. production index primary and level activity activity
efficiency 160 secondary planning planning
(__th period Operations improvement model lines document document
Department policy)
1. Promotion of _____ 3 (2) Acheivement of Q: XXX (1) Initial-phase (1) 10/93 D Section
business plan control through SOP activity
2. Development of target QCD of C: OOO TAPPS activity planning
_____ mass production document
3. Promotion of TPM critical control part
activities
(1) Promotion of production (3) Promotion of Shift __% of (2) (1)
efficiency improvements Completion
(2) Production initial-phase indirect operations model Implementation by 1/93
control
efficiency department of secondary
Reaching QCD targets
(3) Promotion of indirect improvement personnel model for four

departments

Diagnosis Execution Project by theme Departmental level project Team improvement activity

Execution based on activity plan

President diagnosis Block Manager diagnosis Department Manager Department Manager

diagnosis diagnosis

© JIPM

Background and Purpose of 4 2-3
Introducing TPM (Plant)

Background to and Purpose of Introducing TPM

Background

External environment Internal environment

(1) Increasingly severe competition beyond the (1) Structural reform activities are stagnant.
framework of the keiretsu corporate group (2) Three detrimental factors are increasing in newly

(2) Demand by customers for discounts developed aluminum radiators: "Equipment
becoming stronger each year failure," "minor stoppage" and "process defects."
(3) Volume continues to increase, causing delivery
problems.
(4) Improvement does not progress because
we are preoccupied with the pursuit of
quantity.

Promotion of TPM activities

Basic policy Purpose of activities

Promote PM with the participation of all To change our behavior, our philosophy, and our view of
personnel, and create a stronger company and things.
a motivating workplace through activities that (1) Create a workplace in which people can work
target zero injuries, zero failures and zero
defects. without accidents and with peace of mind.
(2) Create equipment and lines that do not produce

defects.
(3) Pursue reduction of unit costs to the utmost.
(4) Work toward the training of personnel.
(5) Create a pleasant workplace environment.

Three things for a factory to implement

Desire to purchase Desire to work Make money

A factory that produces A factory in which workers feel a A factory that eliminates
products customers sense of satisfaction by working all waste and
want to buy in a pleasant environment, and in continuously carries out
which workers have hope for the improvement.
future.

People Things Equipment Information

Priority activity items and targets

Target: End of March, 19__
* Labor productivity: 140% ..................................................................................................................... 140 %
* Overall equipment efficiency: 85% ...................................................................................................... 85 %
* Set-up time: 1/2 .................................................................................................................................. 1/2
* Reduction of equipment failure time: 1/10 ........................................................................................... 1/10
* Reduction of process defects: 1/5 ....................................................................................................... 1/5

© JIPM

Policy and Goals of TPM (Plant) 4 2 - 4 - (1)

Policy and Goals of TPM

Background

External environment Internal environment

Increasing deterioration of domestic markets Worsening of sales and profitability
(1) Demand from manufacturers to reduce unit
Worsening of the export environment costs
(strengthening of the yen currency and (2) Trend toward worsening of exchange rate
localization of production overseas) losses (direct deliverables)

Rapid development of the level of technology Diversification and advancement of quality and
Shedding of old technology functions, and dramatic reduction in unit costs
(new materials and new products)
Loss of domestic production due to overseas
production

Needs of management

Promotion of reform through company-wide Promote autonomy of overseas offices and
implementation of TPM improve profitability.

Increase competitiveness for current products Establish an optimal production system,
and cultivate new product groups through the and promote the creation of products that
maximal pursuit of the target quality. are high in quality and low in cost.

Promote product development and Pursue target profit through the promotion
development of processing techniques that of sales expansion and overall reduction in
lead the market. unit costs.

Basic policy and targets

Basic policy

Through the participation of all personnel in PM, create lines that achieve "zero injuries, zero defects, zero
failures, zero set-up and zero minor stoppage losses." Strive to improve the efficiency of equipment and
people, reduce unit costs, and create a stronger company and a motivating workplace.

Purpose of activities

To change people, to change equipment, and to realize a factory that yields high earnings and is bright and easy to work in.

Creation of a "spirited" plant

Assembly workplace Specific targets Equipment workplace
(1) Zero injuries
• Creation of lines easy on employees (2) Zero defects • Improvement of overall equipment
(Standard work procedures (3) Zero failures efficiency
that anyone can perform in (4) Zero set-up (Overall equipment efficiency
the same manner.) (5) Zero minor stoppages of 85% or greater)

(1) Number of accidents requiring suspension of (6) Delivery defect rate: 1/5 or less
operations: 0 (20 million hours) (7) Minor stoppage time: 0

(2) Labor productivity: 150% Number of cases: 0
(3) Overall equipment efficiency: 85% or more (8) Reduction of disposal cost: 1/3 or less
(4) Equipment failure time: 1/10 or less (9) Improvement suggestions: 100

Number of cases: 1/10 or fewer suggestions/person or more
(5) Set up time: 1/3 or less (10) Attainment of skilled technician status: 65

persons or more

© JIPM

Policy and Goals of TPM (Plant) 4 2 - 4 - (2)

3SPM Policy and Targets

In order to bring about "leeway and abundance," this company issued a company-wide long-term
management vision statement in April 1990. In line with this plan, this Operations Department has formulated
the "New Troika" midterm plan. Taking "challenge and creation" as our philosophy of action, we have resolved
to introduce TPM with the cooperation of all personnel of the company and with the aim to shift from quantity to
quality.

Relationship between TPM and Company/Operations Department Policies

1985-89 90 91 92 93 94 95 2000

Company "Company-wide long-term management vision" (90-92-95-2000) Global 2000
long-term Worldwide system
Vision Action 92 Innovation 95
Management reform Management innovation

Operations "Promotion of fiscal year "Music box operations department midterm plan" (91-95) Year 2000
Department Music boxes
Policy management plan" "Promotion of New Troika" Koen Plant

• Starting up line (1) Completion of 3S --> all out pursuit of profit

• Modification and correction (2) Implementation of high quality music boxes --> creation of culture

of bottleneck processes (3) Cultivation of ONP (new products) --> reform toward next generation

Project Project to create 3S track TPM with participation of all personnel
Implementation
Expansion of quantity, Award for PM excellence Consistent TPM Special award for TPM
speedier cycle time, line commitment award achievement
start-up, etc.
Centered on engineering- Shift from quantity to quality Reform toward the next generation
related staff
Promoted with the participation of all Integration of sales, development and
personnel production

Policy and targets of TPM activities

TPM activities aim to create a plant best suited for the workers, customers and society (of the region).

Background to the introduction of TPM

Market Equipment People
Total demand > production capability
• Failures and minor stoppages are • Decline in disposition to improve
Not fulfilling our responsibility as the becoming chronic productivity and productive capability
top manufacturer of music boxes
• Cannot predict the service life of equipment • Repair equipment after it fails (leaving it
(Responsibility to supply) • Left to forced deterioration to other people)

(Inadequate equipment management) (Lack of desire to take up the challenge)

Sense of crisis about losing market share Sense of crisis that investment will be wasted

Decision to introduce TPM

Let's maximize output through effective utilization of resources!

(Slogan)

With the full participation of all personnel, let's make the _____ Plant an impeccable factory!
Let's pursue 3S! ( 3S as in three satisfied groups: Employees, Customers and Society)

Our TPM activity is called "3SPM"

Note: The TPM activity of Sankyo Seiki Mfg. Co., Ltd. is referred to as 3SPM.

© JIPM

The Shift from DPM Activity to ZPM 4 2-5
Activity

The Shift from DPM Activity to ZPM Activity

ZPM activity is a "company-wide reform activity" that forms
the core of the new enterprise movement

This company started DPM activities (TPM Part I) in 1986 and received the award for PM excellence in
fiscal 1989.

The Production Division, comprised of the Business Operations Department and Engineering
Headquarters, has carried out DPM activities and achieved great results.

The year 1989 marks the 50th anniversary of the founding of this company. Looking forward to the next
50 years, it is urgent that we make reforms to realize our corporate vision in the 21st century. Against this
backdrop, we have given the name "new enterprise movement" to all activities engaged in this reform,
starting with CI. In this connection, the company issued the New Enterprise Declaration in October 1990.
On the same day and at the same venue, ZPM activities (TPM Part II) were started as the core activity of the
new enterprise movement.

86 89 90 91 92 93 2000-

DPM kick-offChange corporate philosophyReconstruct philosophy and image
and company name
Start new enterprise Receive award for
Develop new form movement PM excellence SS
CS GS
Introduce CI
ES
New enterprise ZPM kick-off

declaration
Receive award for
excellence in
consistent PM
commitment
Receive special
award for PM
achievement

Excellent company for the 21st century
Subcommittees by operation Reconstruct operation structure

Personnel and organization Reevaluate systems
task force

DPM (TPM Part I) ZPM Construct an excellent
(Part II) production system

SS: Social Satisfaction CS: Customer Satisfaction
GS: Global Satisfaction ES: Employee Satisfaction

Note: The TPM activity of Diesel Equipment is referred to as DPM. The TPM activity of the subsequently
renamed company, Zexel, is referred to as ZPM.

© JIPM

Solicitation Requirements for TPM 4 3-6
Activities Slogan

__/__/__
TPM Promotion Office

To: Sections and Offices

TPM Activity Slogan Solicitation

With the participation of all company personnel, TPM activities will finally
start on __/__ . In order to implement this activity enjoyably and with hope
for the future, we ask everyone to rise to the challenge and contribute your
ideas for a slogan.

Information:

1. The slogan should:
(1) Concisely express the objective
(2) Incorporate ideas about activities
(3) Express everyone's dream
Please feel free to express other concepts in your slogan.
Example
"Let's create a dream factory for the 21st century through TPM!"

2. Deadline: __/__ (______day)

3. Submit to: TPM Promotion Office

4. Judging: One person will be selected from each departmental meeting for the screening committee.
The primary judging will reduce entries to 10 slogans, and then all personnel will participate
and cast their ballot in the secondary judging. Subsequently, the TPM Promotion Committee
will make a decision.
Election ballots will be distributed separately to each section.

5. Other
Commendations will be given at the kick-off ceremony. Further, a prize will be given to the winner.

© JIPM

Activity Policy Imple

Improvement of Ensuring safe operation Accident and failure losses
level of safety and Ensuring environmental
Environmental claims
environment maintenance
management Improvement of efficiency Equipment strategy Construction plan and
through strengthening and design losses
Improvement of Improvement of overall efficiency Construction work
profitability advancing equipment administration losses
Improvement of overall equipment efficiency
Training people High efficiency and Effective utilization of
and creating a maximum utilization of Improvement of quality various yields
Successor to corporate philosophy
workplace current equipment Diffusion of SDM
Promotion of employee training Equipment failure losses
Improvement of attitudes Promotion of skills development
toward working on problems Accumulation and utilization of technology Energy losses
Charge down losses
Improvement of technical Slope down losses
skills
Catalyst losses
Promotion of health and Utilities losses
cultural life Quality losses
New quality assurance
Creation of a workplace
environment ISO and PL

Promotion of health
Improving satisfaction with one’s lifestyle
Improvement of workplace environment
Improvement of methods to advance work

ementation Diagram Activity Policy Implementation
Diagram
Safety and Environment Activities * Accidents and failures: 0
* Establishment of identifying potential dangers and * Environment abnormalities: 0 4 4-7
utilization of the information to improve safety * Number of cases of indentifying potential
* Observance of regulatory standards or actual danger and utilization [for
* Utilization of work mechanisms safety/environment] : __ cases/person-
* Promotion of equipment quality assurance month
* Thorough safety management at related companies * Reduction of inspection and operating time:
* Making efforts to create an earth-friendly environment __% reduction (compared to fiscal year __)
* Number of cases of individual improvement:
Autonomous maintenance activities __ cases/Gr.-year
* Implementing the 7 steps of autonomous maintenance * Number of cases of one-point lessons
created: __ cases/Gr.-year
Planned maintenance activities * Maintenance expenses: $___,___,___
* Reduction of maintenance expenses reduction (average of year __)
* Ensuring equipment reliability * Number of cases of developing and
* Autonomous maintenance support activities introducing predictive/forecast technology
or equipment diagnosis technology: __
Equipment initial-phase control activities cases (fiscal year: __)
* Strengthening of construction work * Reduction of investment costs:
* Full-scale production after one-shot start-up of new $___,___,___.
equipment and modified equipment * Full-scale production after start-up of new
* Strengthening of MP design or modified equipment: Within __ days
* Strengthening of MP information
Equipment efficiency improvement activities
* Improvement of equipment production efficiency * Improved earning power: $___,___,___.
* Establishment of stable operation of new equipment * Energy savings: ___ ,000 FOE-kl
* Ensuring midterm utilities supply capability
* Promotion of studies on next-period equipment * ISO certification: Fiscal year: __
advancement * Result of improving quality: $___,___,___.
* Promotion of technology development
* Level of cost awareness: __% increase
Quality improvement activities * Qualifications earned: __ cases/person-year
* Acquiring ISO certification * Correspondence courses: Participation rate:
* Optimization of quality and utilization of yields __%
* PL countermeasures
Completion rate: __%
Educational activities * Training of maintenance engineers
* Support activities for other departmental meetings * Training of maintenance technicians
* Support activities to improve awareness of cost * Participation rate in work improvement
* Training of operating departments activities: 100%
* Training of company employees performing clerical * Reduction of curtailable expenses:
and administrative work $___,___,___
* Strengthening of work improvement activities * Number of cases of standardization: __
cases
Work efficiency improvement activities * Number of cases of abolished standards: __
* Autonomous maintenance activities through "work cases
standardization" * Number of cases of office automation: __
* Individual improvement activities to eliminate losses cases
* Individual improvement activities done by on each * Efficiency improvement time: __,___. hours
section * Reduction of sickness rate: Less than __
* Creation of streamlined offices * Participation in physical strength
measurement: __%
Lifestyle activities * Number of certifications for pleasant
* Promotion of health workplace: __
* Improvement of the level of satisfaction in the * Improvement in level of satisfaction with
workplace and in one's personal life lifestyle: __%
* Equipping the facilities
© JIPM

Target Developmen

The benchmark is zero _______ by the year __,

(Target implementation -1) (Target implementation -2)

Amount Contribution Am
(unit:¥million) rate (%) (unit:
Safety and Environment Activities Reduction in production losses

Reduction in variable expense
losses

Amount Contribution Careful selection of work items
(unit: ¥million) rate (%)
Planned maintenance activities Improvement of production
methods, corrective maintenance

Reduction of work expenses
Extension of continuous operation

Reduction of maintenance
expenses and losses

Other

Amount Contribution Etablishment of operations to
(unit: ¥million) rate (%) restrict JOB
Equipment initial-phase control
Identification of ways to improve
design specifications

Curtail expenses for
consumables

nt Diagram Target Development Diagram

, and the target is the average___ in the year __.

(Target implementation -3)

mount Contribution Set target values for fiscal year 4 4-8
: ¥million) rate (%)
1993 1994 1995 1996 1997 Average of
Subtotal 1996 and 1997

Subtotal Planned
Subtotal Actual
Planned
Actual

Planned
Actual
Planned
Actual
Planned
Actual
Planned
Actual
Planned
Actual
Planned
Actual

Planned
Actual
Planned
Actual

Planned
Actual

© JIPM

Critical Tasks and Targ

Activity Name Critical Task
Safety and Environment Activities
• Establishment of identification of potential d
Autonomous maintenance activities utilization [for safety/environment]

• Observance of regulatory standards
• Utilization of work mechanisms
• Making efforts to create an earth-friendly en
• Implementing the 7 steps of autonomous m

Planned maintenance activities • Reduction of maintenance expenses
• Ensuring equipment reliability
• Autonomous maintenance support activities

Equipment initial-phase control • Strengthening of construction operations
activities • Full-scale production after start-up of newly

Equipment efficiency improvement equipment and modified equipment
activities • Perfection of MP design
Quality improvement activities • Improvement of equipment production efficie
Educational activities • Construction of new equipment and establis

Work efficiency improvement stable operations
activities • Acquiring ISO certification
• Quality optimization activities
• Support activities for other departmental me
• Support activities to improve awareness of c
• Maintenance technology, and training of tec
• Training of company employees performing

administrative work

• Autonomous maintenance activities through
standardization"

• Individual improvement activities to eliminat
• Creation of streamlined offices

get Values by Activity Critical Tasks and Target Values by
Activity
dangers and Target Value

nvironment • Accidents and failures: 0
aintenance • Environment abnormalities: 0
• Number of cases of idenfication of potential or actual
s
danger and and utilization [for safety/environment]:__
added cases /person-month
ency
shment of • Reduction of implementation and operation time: __%
reduction (compared to fiscal year __)

• Number of cases of individual improvement: __
cases/Gr.-year

• Maintenance expenses reduction: ¥___,___,___.
reduction (year: __)

• Number of cases of developing and introducing predictive
technology or equipment diagnosis technology: __ cases
(fiscal year: __)

• Reduction of investment costs: ¥___,___,___
• Full-scale production after start-up of newly added

equipment or modified equipment: Within __ days
• Strengthening of MP information
• Improvement in earning power: ¥___,___,___.
• Energy savings: __,000 FOE-kl

eetings • ISO certification: Fiscal year: __ 4 4-9
cost • Result of improving quality: ¥___,___,___.
chnicians
clerical and • Level of cost awareness: __% increase
• Training of maintenance engineers: __ persons or more
h "work • Training of maintenance technicians: __ persons or more
• Qualifications earned: __ cases/person-year __
te losses • Correspondence courses: Participation rate: __%
• Completion rate: __%

• Number of cases of standardization: __ cases
• Number of cases of computerization (Office Automation):

__ cases
• Number of cases of abolished standards: __ cases
• Efficiency improvement time: ___,___. hours
• Reduction of expenses: ¥___,___,___.

© JIPM

Basic Approaches to S

(1) Targets shall be set from the following three viewpoints in order to atta

1) Quantitative target values that directly affect profits (indicate on

2) Quantitative target values that indirectly affect profit (time, man-

3) Qualitative targets (descriptive wording and indices)

(2) The benchmark shall be fiscal year ‘__, and the target fiscal year sh

progress can monitored along the way.

(3) The basis for setting target values in 1):

… Target value: Profit stated as ¥__million improvement (compa

… Basis: • As a result of comparing other companies fo

will be set as our current target.

• Aiming to catch up to and surpass _______
Fiscal ‘__ average earnings comparison: ¥_
Future profit increase at ______ Plant: ¥_

Accordingly, we are aiming to increase profits by ¥___,___,___

(4) Target values for each of the following items shall be set in order to

• Additional production amount: ¥___,___,___.

Breakdown Equipment investment related: ¥___,

Operation improvements related: ¥___,

Individual improvement related: ¥___,

Quality improvement related: ¥___,

• Maintenance expense: ¥___

• Reduction of problems/malfunctions: ¥___

• Variable expenses: ¥___

• Other fixed expenses: ¥___

• Increased depreciation and amortization expenses, etc.: -¥__

Setting Targets Basic Approaches to Setting Targets 4 5 - 10

ain the goal of becoming the country’s most profitable factory:
nly by amount)
-hours and number of suggestions)

hall be ‘__. Further, targets shall be set for each fiscal year so that

ared to fiscal year ‘__)
or fiscal year ‘__, _______ Plant, which is the most profitable plant,

Plant in terms of absolute amount of profit.
___,___,___.
___,___,___. (data based on fiscal year ‘__ management plan)

_.in order to catch up and surpass these figures.

o increase profits by ¥___,___,___.

,___,___. Target:
,___,___. ¥___,___,___
,___,___.
,___,___.
_,___,___.
_,___,___.
_,___,___.
_,___,___.
__,___,___.

© JIPM

JIPM - TPM® 600 Forms Manual
Sample Formats for the12 Steps of TPM

5. TPM Master Plan

© JIPM

5. TPM Master Plan (1) 1 Department Activity Planning Chart
(2)
1 Basic Company-Wide TPM Policy (3) 2 Model Line Activity Planning Chart
Basic Plant TPM Policy Specialized Departmental Meeting
Activity Plan for Each
Department 3 Activity Planning Chart

Model Line Activity Plan
Specialized Departmental
Meeting Activity Plan

Catch the ball

Three-Year Master Plan (4) 4 Master Plan
Annual Action Plan
(Detailed Plan)

© JIPM

_____ Departme

Specialized activity Department implementation (goal) 19__ 10 11
12 1 2 3 4 5 6 7 8 9
Individual * Realization of zero losses in all areas Utiliz
Understanding and structuring of 16 major losses
improvement activity such as failures, defects, etc.
Creation of things "as they should be"
• Understanding of 16 major losses
Study meeting for PM analysis
• Implementation of overall efficiency

improvement

* Pursuit of maximum productive
efficiency
• Implementation of PM analysis
• All-out pursuit of things "as they should
be"

Autonomous * Training of operators proficient with Implementation of the 7 steps of autonomous maintenance (mo
maintenance activity equipment
Step 1 Step 2
• Implementation of autonomous
maintenance step Individual impro

*Establish system in which individuals
take care of their own equipment

Step 1 Step 2

___ Plant circle conference ___ Plant circle

Planned * Selection of MP information

maintenance activity * Mastering maintenance skills Selection of MP information and creation of MP information s

• Autonomous maintenance rate Post-overhaul full-scale
production after start-up
• Maintenance calendar

• Measurement of degradation

Quality maintenance * Establishment of a control system and Increasing the a

activity creation of conditions so that defects do Verification of quality characteristics standards, and
understanding of defect phenomena and actual record
not occur
Investigation of
conditions that build in

Setting of 4M conditions so that defects

Educational * Comprehension of operations and JIPM seminars and
activity maintenance skills education/training correspondence courses
• Acquisition of maintenance skills
• Acquisition of operations skills Mutual correspondence cours
• Acquisition and practice of TPM
techniques Participation in maintenance Participation i
technician training technician tra

Challenging the _____ maintenance Participation in t
technicians for _____ Plant

Safety and health * Achievement of zero accidents 5S activities at locations common to departments (confere
activity • Implementation of periodic safety patrols

* Implementation of a spirited workplace ___ safety patrol ___ safety patrol __
that is healthy and motivating

ent Activity Plan 19__ Department Activity Plan

1 12 1 2 3 4 5 6 7 8 9 10 11

Preliminary Assessment On-site Screening

zation of PM analysis and all-out elimination of 16 major losses through implementation of individual improvement

odel) Step 4 Step 5 Step 6
Step 3
Horizontal
ovement implementation

Step 3 Step 4 Step 5 Step 6

e conference ___ Company-wide circle conference ___ Plant circle conference ___ Plant circle conference

sheets through autonomous maintenance activities and individual improvement activities

Measurement of Creation of
degradation maintenance calendar

autonomous maintenance rate

Investigation, analysis and Setting 3M conditions and setting
correction of problems inspection standard values

Creation of standards 5 1-1
that can be adhered to

s do not occur, and creation of a system that correctly controls these conditions

ses focusing on one-point lesson sheets, and various study-meeting techniques

in maintenance Participation in maintenance Participation in maintenance
aining technician training technician training

the planning of preparatory courses Challenging the _____
certified maintenance technicians maintenance technicians

ence rooms, lounges, etc.) ___ safety patrol
__ safety patrol ___ safety patrol

© JIPM

Model Line Ac

Implementation Introductory Preparation Diffu
Fiscal Year Period Fiscal ‘__

Item Fiscal ‘__

Kick-off

Master Plan Step 0 Step 1

Management model
Autonomous maintenance

Formal Organization Model Steps 0 - 3 Step 4 S
Implementation
Individual improvement

Horizontal
implementation

Ho

Department Model Model line Autonomous mainte
Steps 0 - 1
Individual Equipment
Large Individual Individual im
Equipment
Horizo
impleme

Autonomous maintenance
Machine No. 1

Individual im

Circle Autonomous maintenance Steps 0 - 3
Machine No. 2

Individual improveme

Activities Plan Model Line Activities Plan

usion and Practice Period Strengthening and
Establishment Period

Fiscal ‘__ Fiscal ‘__
Preliminary Assessment On-site screening

Step 2 Step 3 Step 4 Step 5 Step 6

Step 5 Step 6

Horizontal implementation
Horizontal implementation
orizontal implementation

enance Step 3 Step 4 Step 5 Step 6
Step 2

mprovement

zontal
entation

Steps 0 - 3 5 1-2
mprovement

Step 4 Steps 5 - 6

ent Steps 0 - 3
Horizontal implementation
on other equipment

© JIPM

Sub-committee Meeting Activity Plan (Example of Auton

Year Year ‘__

12 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3

Overall targets

Progress level Kickoff conference
evaluation
Model line and model equipment Co
C
7th step equipment C

4th step equipment Com

3rd step equipment Department 5S

Department 5S activity and Achievement of theme: __ cases
evaluation points
Individual improvement theme __ points
activity
PM checklist departmental meeting Example o
evaluation
Level evaluation of management
index

Executive meeting: once/week

Leader meeting: once/3 months

Operating Body Circle leaders meeting: once/2
months

Autonomous maintenance
departmental meeting:
twice/month
Instructors guidance meeting:
once/3 months

Autonomous maintenance day:
twice/month

Activity details Circles In-house Plant Plant East Company-
conference Suggestions Facilities wide

conference Outside Women's conference PM impr
conference

Implementation of events One-point lesson Problems "Thi

PR activities (bulletin)

nomous Maintenance Departmental Meeting) Sub-committee Meeting
Activity Plan
Year ‘__ Year ‘__

4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12

Submit synopsis Examine Main
documents examination
Preliminary assessment application period
Preliminary assessment period Pep Rally

Pep Rally

ompletion of 4th step (___%) Completion of 6th step (___%)

Completion of 4th step (__%) Completion of 6th step (__%) (___%)-__
Completion of 4th step (__%) Completion of 4th step (___%)

mpletion of 3rd step (__%) Completion of 3rd step (___%)

S check evaluation points: __ points __ points _ points or greater
Achievement of theme: __ cases __ cases or greater
Achievement of theme: __ cases

__ points __ points _ points or greater
of overall equipment efficiency: __% Overall efficiency: __% __% or greater

Plant Plant East Company- Plant Plant 5 1-3
rovement conference wide
facilities Women's
conference
Women's conference Maintenance calendar

ings as they should be" Show off New jigs Visual controls
your skills

© JIPM

Master Plan 5 1-4

Master Plan ‘__

Year ‘__ ‘__ ‘__ ‘__ Establishment Period
Purpose
Activity Introduction Preparation Practice Period Strengthening Period Receive award for
PM excellence
Planned Organize a promotion organization and overlapping small group Preliminary
organization, and establish a Promotion Office Assessment
Maintenance

Set the policy implementation, goals, slogan and results targets
Formulate the master plan

Individual 1.5-fold overall efficiency plan
Improvement Organize improvement teams
Activity (elimination Select improvement themes
of losses)

Improvement activity (model screening --> horizontal implementation)

Autonomous Step 1 Step 2 Step 3 Step 4 Steps 5 and 6
Maintenance
Activity (elimination Preparation for introduction (introduction declaration of __/__/__) Implementation of step 7 General inspection correspondence course
of 4 faults) TPM kickoff (__/__/__)
Interest-generating activities (TPM news, activities board contest, activities presentation meetings, etc.)
Planned
Maintenance Create planned maintenance system Development of major classifications, periodic maintenance and predictive maintenance
Activity (zero
failures) Lubrication and spare parts systems (model screening --> horizontal implementation)

Activity to achieve zero equipment failures (model screening --> horizontal

Quality (Model advancement)
Maintenance Matrix 3M analysis Table of problem countermeasures FMEA and PM analysis Countermeasures Improvement and standardization
Activity (zero
defects) (Horizontal implementation)
Matrix 3M analysis Table of problem countermeasures FMEA and PM analysis Countermeasures Improvement and standardization
Initial-phase
Control Activity Product (CMreoadteel ianditviaaln-pcheamseenct)ontrol system Trial run Implementation
(full-scale
production after Accumulate and utilize data
start-up)
Create initial-phase control system Trial run Implementation

Trial run Collect and accumulate MP

Education and Create an education system Create an individual skills development system
Training Activity Maintenance skills training
(training employees
to be proficient in Step 1 Step 2 Step 3 Step 4 Step 5
equipment and
work) Work improvement Step 5 Implement warehouse and storage space Step 4
Administrative/Indir Accounts settlement-related clerical work efficiency improvement Production control system improvement
ect Activity
Spirited 5S activity
Safety and Health
Activity Support for autonomous maintenance activity safety
General safety inspection manual
General safety inspection
Daily safety administration activity

© JIPM

JIPM - TPM® 600 Forms Manual
Sample Formats for the12 Steps of TPM

6. TPM Kickoff and PR

© JIPM

6. TPM Kickoff and PR

1 Kickoff Preparation (1) (2) Schedule Up Until Kickoff
Poster 1 Conference
Determination of Daily Schedule
PR Activity (3) 2 Event Plan
Creation of Preparation Schedule (4) (5) Detailed Schedule up Until Kickoff
Selection of Venue
(6) (7) 3 Conference
Division of Roles Venue Layout Diagram for Kickoff
(8) (9) (10)
2 Kickoff Conference 4 Conference

5 Supplies List
Division of Roles Table for Kickoff

6 Conference
Announcement of TPM Kickoff

7 Conference
Emcee Manual for Kickoff

8 Conference

9 Program for Kickoff Conference

Diffusion Activity (11) Follow-up for 10 Conference Slogan (Example)
Non-participants Publish Article in Company

11 Newsletter

• Show Kickoff Conference Video • Summary

Social Party (12) (13) Social Party Program for Kickoff
12 Conference

Division of Departmental Roles for
13 Social Party at Kickoff Conference

© JIPM

Schedule Up U

Month 67 8

Creation of Establishment of Establishment of Organizing
Promotion TPM promotion promotion departmental meeting
Mechanism office organization organization

Introduction Executive course Appointment of
Education by 1-day seminar person in charge
Level of promotion

Participation in TPM College

Participation in JIPM-sponsored seminars and lecture
(Section Managers, Subsection Managers,Group Man

Walk-through diagnosis Introduction education (Plant Manager and Section Managers)

Introduction education (Subsection Managers and Circle Leaders

Creation and examination of the definition

Draft of Master
Plan

Formal Preliminary Drafting of Autonomous maintenan
Organization education a plan Imp
Model
Introduction education correspon
Circle

Until Kickoff Conference Schedule Up Until Kickoff Conference

9 10 11 12

Reevaluation of circle organization

Managers Course (Section Managers) Kickoff
confe-
es rence
nagers and Promoters)

Meeting to show video on autonomous maintenance

rs)

n of loss Setting targets
Investigating a vision
Creation of [the concept
of] the way things
should be

Creation of a master plan

nce activity Summary announcement and creation of a 6 1-1
horizontal implementation manual

plementation of individual improvement

ndence course Preparation to introduce autonomous maintenance activity

© JIPM

Event Plan 6 1-2

Route for plan approval: Person-in-charge → Subsection Manager→ Section Manager → Plant Manager
Route for report approval: Person-in-charge → Subsection Manager → Section Manager → Plant Manager

Event Plan Plant Section Subsection Person-in-
Manager Manager Manager charge

Date Created: __/__/19__

Event name TPM kickoff conference and party

Date and time __/__/19__ Kickoff conference: __:__ - __:__

Party: __:__ - __:__

Venue Cafeteria

Person in charge of planning Section Manager ______

Planning budget ¥______ (Budget code: ___-__)

Planning Details

(1) Purpose

• To inform everyone of the declaration to introduce TPM, the policy goals and activity plans, and to verify in front of everyone

the decision to pursue TPM to the end.

• To introduce an example of implementing a formal organization model activity, and to have everyone recognize the

importance of autonomous maintenance activities.

(2) Refer to attached document (next page) for detailed schedule.

(3) Guests

JIPM officials Mr. ______ and Mr. _____

Six cooperative companies (_____ Transport, _____ Construction and _____ Electric, etc.)

(Decision Approval)

Plant Section Subsection Person-in-
Manager Manager Manager charge

Implementation Status

(1) Participants

• Guests: JIPM officials Mr. _____ and Mr. _____, and six cooperative companies

• Top Management: Executive Director, Managing Director and Plant Manager

• 233 employees

(2) Implementation status

We have thoroughly informed all employees, through the TPM kickoff conference, of the policy target and activity plan of the

TPM activities.

(3) Expenses

¥ __,___. (Venue preparations and refreshments) (Report Approval)

Plant Section Subsection Person-in-
Manager Manager Manager charge

© JIPM

Detailed Schedule Up Until Kickoff 6 1-3
Meeting

Detailed Schedule Up Until Kickoff Meeting

Confirm those to be awarded contest prizes, and purchase the prizes
Examine posting of one-point lesson sheets

Verify document contents

Verify in-house and Day of the conference
JIPM participants

Secure venue
(VIP, GR)

Verify conference program Make arrangements for Set up reception
lunch boxes Make arrangements for tea,
Send out announcement letter napkins and taxis
within the company, outside the Set up reception
company and to JIPM Verify party details
and place orders

Request banner and
prepare venue

Create reports and Distribution
documents

Division of Roles at Kickoff Conference

Venue
• Planning and operations: The autonomous maintenance departmental meeting and the Promotion Office should consider

a plan to liven up the conference.
• Venue preparations: Starting from 1:00 PM on the day before the event

Person in charge: Departmental meeting [members] of each department, promoters and the Promotion Office
• General Emcee: Subsection Manager ______
• Follower microphone: Promotion Office
• Clean-up Starting from 9:00 on __/__

Person-in-charge: All Group Managers and the Promotion Office

Party Venue

• General Emcee: _______

• Venue preparations: Starting from 3:00 PM on the day before the event
Person-in-charge: Departmental meeting [members] of each department, promoters and the Promotion Office

• Planning and Operations: The autonomous maintenance departmental meeting [members] and the Promotion Office
should consider a plan that livens up the conference.

• Clean-up: Everyone cleans up on that day.

© JIPM

Whiteboard Whiteboard North Air Venue Layout Diagram for the Kickoff
Activity policy board for conditioner Meeting
each departmental meeting Whiteboard Whiteboard Whiteboard Whiteboard Whiteboard

One-point lesson sheet board, problem correction sheet and individual improvement sheet board Autonomous maintenance activity
bd

Activity board, _____ Construction S1 slogan Venue Layout Diagram for the Kickoff Meeting
top excellence _____ Electric S2 slogan
Production slogan East
Pillar Pillar Section Manager _____ Engineering slogan
Branch Manager _____ Administration slogan Celebration and TPM kickoff conference
Activity board, Slide projector Mini slogan Plant slogan
excellence award Section Manager_____ Grand slogan Company flag
Department Manager_____
Kitchen Activity board, Department Manager _____ OHP Screen
excellence award
JIPM Mr. _____ Podium, flowers and stage set Microphone
Activity board, JIPM Mr._____
excellence award Managing Director_____
Director_____
Director_____

Pillar Plant Management 6 1-4
Plant Management
258 seats Plant Management Event program Emcee_____ Pillar Backstage
microphone Audio
Pillar

© JIPM Photograph Activity board formal organization C Photograph Activity board formal organization B Photograph Activity board formal organization A

Supplies List 6 1-5

Supplies List

No. Supply Item Name Qty. Storage Person-in- Remarks
Location charge
1 Banner (TPM kickoff 1 Record slogan
2 conference) 1 Create a new one __________ Install the day before
3 Company flag 1 __________ Install the day before
4 TPM flag 7 Warehouse No. 2 __________ Decided by the
5 Conference slogan for 6 __________ department
6 each department 1 Warehouse No. 2 __________ Install the day before
7 Stage 1 set __________ Install the day before
8 Podium 14 Create new ones __________
9 Broadcast equipment 1 (300 x 2500) __________ List of guests
10 Guest seat placards 1 Cafeteria __________
11 Event program 8 __________ For person to expedite
12 Table 9 Cafeteria __________ the proceedings
13 Activity board for each 258 __________ Excellent activity
14 circle 1 Cafeteria broadcast __________ boards
15 Whiteboard 260 equipment __________
16 Chairs 1 Create new ones (A- __________
17 Flowers 2 4) __________
18 Lunch boxes for that day 1 Create a new one __________
19 (guests and employees) __________
20 Video camcorder Meeting room
21 Camera
22 Cassette tape Each circle brings its
23 own
24 Rental
25
26 Cafeteria
27
28 Place order with
_____ Flower Shop
_____ Cafeteria

Warehouse No. 2

Warehouse No. 2

Warehouse No. 2

© JIPM

Division of Roles for Kickoff 6 1-6
Conference

Division of Roles for Kickoff Meeting

No. Role Persons Section-in- Person-in-charge
charge
1 Conference Committee Chairperson 1
2 6 ____, ____, ____,
3 Conference Operations Committee 1 ____, ____, ____
4 Members 1
5 Emcee (Proceedings) 1 Department in charge of
6 1 operations
7 Timekeeper 2
8 2
9 Assistant (Female)
10 2
11 Person in charge of broadcasting 1
12 2
13 Person in charge of lighting 1
14
15 Person in charge of wireless Promotion Office
16 microphone
17 Person in charge of venue Promotion
18 preparations Office
19 Person in charge of creation of Promotion Office
20 signs/banners
21 Person in charge of lunch 6 Conference Operations
22 Committee
23 Person in charge of reception desk
24
25 Person in charge of cameras
26
27 Create program

Create letter of announcement

Prepare consumables (thumbtacks
and cellophane tape)
Prepare examination chart (binder and
writing implements)
Prepare party

© JIPM