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TPM PROCESS PRINCIPLES ANALYSIS OF THE IMPORTANCE OF DEVELOPED
COUNTRIES
Dilafruz Kasimova
Assistant Andijan State Technical Institute
Abstract:
The introduction of the TPM system into the processes means continuous
improvement in the maintenance of production. Technical work is transferred to production
personnel, who now provide the operator with a better understanding of the equipment and
devices he is working with, its features and capabilities, its importance when involved in
maintenance tasks, helps to work as a team. It facilitates the exchange of experience and mutual
learning, and with all this, employee motivation increases, performance results improve.
Key words :
equipment , system , economical , employee , speed, Machine, system.
The Japan Automobile Maintenance Institute has developed a 7-step method, the purpose of
which is to achieve a change in attitude that is essential for the success of the program. I will
introduce the stages of development after the implementation of the TPM system. (Table 1.3.1)
Management informs the company about the decision to implement the TPM system. The
success of the program depends on the attention given by management to its announcement to
all employees. Psychologically prepare all employees to cooperate in order to meet the
expectations and goals of the TPM program. The company's top management should officially
announce the decision to implement the TPM program in the organization. It will be necessary
to organize company TPM seminars and events. Analysis and improvement of the efficiency of
each of the company's equipment begins. An information system is established and established
to record and analyze data on reliability and stability. The most important, strategic or
production-related equipment, or equipment with chronic losses in the last 3 months, is selected
as the test equipment and corrections are made. After the targeted improvements are
implemented, the results are verified.
Table 1.3.1
Development stages after implementing the TPM system
1
Initial cleaning
A dust removal and lubrication program is carried out, and its
components and equipment are adjusted.
2
Machine cleaning
Avoiding the causes of dust and messy work, improving access
to hard-to-clean and lubricate areas, two main functions are to
reduce the time required for cleaning and lubrication.
3
Preparation
of
lubrication processes
Standard procedures are prepared, cleaned, lubricated
component adjustment work is carried out in a short time.
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4
General inspections
Production staff responsible for minor adjustments are trained
to resolve
5
Autonomous
inspections
Checklists for machines are prepared and put into practice by
the operators themselves
6
Distribution procedure
It is about creating procedures and standards that reflect parts
management and more.
7
Optimization
in
activity
The final stage is continuous improvement across the company,
with time between failures systematically recorded.
Initially, the 7 main losses affecting the overall efficiency of the equipment are analyzed,
prepared, tool replacement, commissioning, minor stops and idle operation, speed reduction and
elimination of defects in the work. Currently, the maintenance department significantly
increases its work due to the requirements created by the groups from the production areas. The
implementation of autonomous maintenance activities by production personnel is self-
maintenance, ensuring that each operator is responsible for the effective care of the equipment
entrusted to them. Maintenance personnel must be fully competent in their work. Compliance
with standard requirements is required to put safety first.
The TPM system is now widely used in many developed countries, including the United States,
Germany, South Korea, and other countries, in addition to Japan. This system is recognized by
global companies as a means of increasing production efficiency, controlling quality, and
reducing costs.
In the US, when implementing the TPM system, large US companies such as General Electric
and Ford introduced TPM in the 1980s. Here, TPM was integrated with ISO 9001-2015 quality
management systems. Companies effectively helped identify waste in production through TPM.
Strengthening the sense of ownership of employees in their workplaces increased efficiency and
achieved goals. Example; After implementing TPM at Ford, equipment downtime was reduced
and product defects were reduced by 45%.
In Germany, as a technology giant, TPM is used in highly automated equipment. BMW, Bosch
and other companies have paid great attention to improving production efficiency through TPM.
They have especially strongly established the principles of preventive maintenance and quality
control. It allows for automated monitoring of equipment condition, warnings and service life
planning.
In Japan, the TPM system has become an integral part of production. Toyota, Nissan and other
giant companies are working on the basis of TPM. The TPM system has been adopted as a key
tool for optimizing production processes. In Japan, TPM is used in conjunction with Kaizen
continuous improvement methods for organizing the workplace. I will cite important factors in
the development of TPM. It is possible to improve the efficiency of production processes .
Their experience is of great importance in the TPM system in optimizing production processes
and increasing the reliability of the overall efficiency of equipment. (Scheme 1.3.1)
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South Korean companies like Samsung, LG, and Hyundai have deeply embedded TPM
principles into their manufacturing culture. Each department is responsible for its own
equipment, and if a problem occurs, the entire team must quickly fix it .
In the Italian industry, Ferrari has implemented the TPM system in its production processes.
This system has helped to increase production efficiency and quality by 18%, while maintaining
high technical requirements in the automotive industry (Table 1.3.2).
Table 1.3.2
Indicators of companies that have implemented TPM
Countries
Companies
Efficiency%
Japan
Toyota, Nissan
75.09 %
Germany
BMW, Bosch
22.7%
Italy
Ferrari
18.12 %
USA
General Electric, Ford
35.4%
South Korea
LG, Hyundai
17.01 %
1.3. 1 - diagram
Indicators of international companies that have implemented TPM
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In conclusion, the correct selection of testing methods to improve product quality. We have
studied the data on the TPM system in the automotive industry and its development in
international enterprises. We can see that Japan's Toyota Motor Company is the most efficient
enterprise in the history of the TPM system, having implemented it to 75.09%.
REFERENCES USED:
1. "Improving production systems in the automotive industry" — textbooks and articles
published in various higher educational institutions of Uzbekistan.
2. "GM Uzbekistan: Improving Production and Technologies" - internal methodological
manuals of GM Uzbekistan.
3. "Effective production management based on TPM" — articles published in scientific journals
of Uzbekistan.
4. Nakajima, Seiichi. "Total Productive Maintenance: A Key to Improved Productivity" — a
book about how to implement TPM methodology in production processes.
5. Hirano, Hiroyuki. "Lean Manufacturing and TPM: A Japanese Approach to Productivity" —
teaches how to apply TPM in Japan.
6. "Journal of Manufacturing Science and Engineering" — a scientific article on TPM and
manufacturing improvement.
5. " Improvement of automotive industry based on TPM, bibliographic analysis " Articles
published in the journals Innovation in the modern education system.[
1
]
6. Introduction of total technical maintenance (TRM -total productive maintenance) / AA
Mamajonov, OO Abdujabborov. –Tashkent. Scientific and technical journal "Milliy standart".
2023. No. 1. 19-22b
