24 February 2009                www.strategosinc.com

Dynamic Effects In TPM

How TPM Builds On Itself In A Virtuous Cycle

Depictions of Total Productive Maintenance (TPM) commonly feature a building with "pillars" that support a roof  of "Lean" resting on a foundation of education and responsible values. While this depiction is helpful, it is insufficient for full understanding.

TPM is a dynamical system, i.e., it changes over time. The dynamic effects are not captured by the "pillar" model. After all, what could be more permanent, static and unchanging than the Parthenon?

Of course, nobody really "believes" in the static model. If the system did not bring changes, why use it? But, the static model leads to an unspoken assumption that improvements are linear. In fact, they are more likely exponential.

Perhaps more damaging, the static model encourages a false belief in the robustness of the system; an assumption that "If we build these pillars then we will always get steadily improving results." In reality, the system is quite sensitive at certain points. The mechanisms that bring exponential improvement can also produce exponential waste.

I have added a new page to our TPM series. It addresses the dynamics of TPM and interactions between TPM and other elements of Lean.

This dynamic model is also in our updated version of "TPM In A Nutshell." The "TPM In A Nutshell" graphic is available as a free download or, for purchase, as a giant 6'x8' banner for the training room or shop.

The broader topic of dynamical systems is terribly important in any organization. Dynamic effects, more than static structure, create most successes and failures. I am planning a series of articles on Systems Thinking and its application in Lean. The current pieces on our site that discuss this topic do not do it justice.

Best Regards,

Quarterman Lee

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