Total Productive Maintenance (TPM) Reading Answers

Jan 21, 2023

Total Productive Maintenance (TPM) Reading Answers is an IELTS academic reading topic. The passage Total Productive Maintenance (TPM) Reading Answers- contains following question types from IELTS Reading Question Types: Summary Completion, True False Not Given Questions, and Multiple Choice Question. This IELTS reading topic comprises no more than three words type questions. To answer the IELTS reading questions, candidates must go through the reading passage properly. More such topics like -Total Productive Maintenance (TPM) Reading Answers can be found in IELTS reading practice papers to practice from.

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Section 1

Read the Passage to Answer the Following Questions

Total Productive Maintenance (TPM) Reading Answers

The ‘production line’ system of creating and assembling goods was for many years been the standard mode of operation for many industries. Cars, electronic equipment, packaging – many diverse companies have employed the same methods, and most have hit two main problems, The first is that unscheduled maintenance required on essential machinery has often held up production all along the line, and the second Is the significant impact on employee morale, This has given rise to the increasingly adopted method of Total Productive Maintenance (TPM) – a maintenance program which governs the maintenance of plants and equipment. The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.
The concept of TPM was first developed in Japan in the late 1970s, only moving to the western world a decade later, initial success of the programme in countries such as Australia was limited, but in the late 1990s a ‘westernised’ version of TPM was launched. TPM brings maintenance into focus as a necessary and vitally important pan of the business. It is no longer regarded as a non-profit activity. Down time for maintenance is scheduled as a part of the manufacturing day and, in some cases, as an integral part of the manufacturing process. The goal is to keep emergency and unscheduled maintenance to a minimum.
TPM involves directing participating companies and industries to move away from traditional methods of production to more efficient mechanisms. This is evident in TPM’s operational focus on lea production rather than mass production. The lean approach favours flexibility within a team, rather than the specialisation of labour Introduced with mass production. It also involves a shift away from being driven by the financial department of the company to a more customer focussed goal. Another goal of the TPM method is to introduce quality control not by being overseen by managers, but rather by engendering a sense if responsibility amongst all staff; a move from autocratic management to empowerment. This shift means that shop floor workers are being able to take a sense of pride in their work, and with that comes the desire to perform well ultimately leading to higher productivity for the company.
in order to apply the concepts of TPM, a company will have to work through a number of stages. First, there must be universal agreement that the system has the potential to be successful within the company. Then a specific person or team needs to be appointed to coordinate the changes required to apply TPM methodologies, an aim that begins with training and education for all employees. Once the coordinator is convinced that the work force is sold on the TPM program and that they understand it and its implications, the first action teams are formed. These teams are usually made up of people who have a direct Impact on the problem being addressed. Operators, maintenance personnel, shift supervisors, schedulers, and upper management might all be included on a team. Each person becomes a stakeholder in the process and is encouraged to do his or her best to contribute to the success of the team effort. Usually, the TPM coordinator heads the teams until others become familiar with the process and natural team leaders emerge.
The concept of TPM is built on what are referred to as the three pillars – work area management, risk management and equipment management. An illustration of these pillars is highlighted in the importance of recognising and eliminating defects within the machinery used in a company, This refers to issues such as the accumulation of dust and grime on equipment, gauges that are broken or too dirty to read clearly and missing or loose bolts, nuts and screws, Using a sample company, statistics collected from a three month period Indicate a substantial reduction in machine maintenance costs, felling by $ 30,000 between 1996 and 1999. At the same time, the effectiveness of the equipment increased significantly, with machine uptime rising by almost 2096 over the same period.
Many observers have identified similarities between TPM and an earlier industry concept – total quality management (TQM), and in many respects, TPM and TQM resemble each other. Both require total commitment to the program by upper level management, and both promote the empowerment of all employees to initiate corrective action, Additionally, both processes require a long range outlook, as it may take a year or more to implement and is an ongoing process, Changes in employee mind-set toward their job responsibilities must take place as well, Indeed, initial results for at least the first quarter may actually lead to reduced productivity while changes are put into effect.
The difference between the two systems, however, becomes apparent in when looking at what each system considers to be a priority. TQM is essentially an output focussed system, whereas TPM is singular in that it looks more at input – the equipment used and the causes of real or potential maintenance failures. Also, although both programme stress the need for complete involvement of all parties, TPM stresses the equal importance of all levels of employee, whereas TQM has a more traditional focus on management structure, The main target of both is also slightly different; whereas TQM alms to improve quality, TPM aims to reduce wastage and minimise losses.

Section 2

Solution and Explanation

Questions 1 – 7

Reading Passage has seven paragraphs A-G.
Choose the correct heading for paragraphs A-G from the list of headings below.

Write the correct number i-x in boxes 1-7.

List of Headings

Unique focus of TPM
Common issues TPM was establish to combat
Statistical weakness of TPM
The introduction of TPM
Parallels with a former concept
Types of TPM coordination and training
Implementing TPM
The guiding principles of TPM
The impact of staff involvement
Efficiency through involving all employees
The value of mass production techniques

Paragraph A

Answer: ii. Common issues TPM was establish to combat
Supporting Sentence: The goal of the TPM program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction.
Keywords: TPM program, increase production while, job satisfaction.
Keyword Location: Paragraph A
Explanation: The paragraph relates to the two fundamental issues addressed by TPM.

Paragraph B

Answer: iv. The introduction of TPM
Supporting Sentence: The concept of TPM was first developed in Japan in the late 1970s
Keywords: developed in Japan
Keyword Location: Paragraph B
Explanation: TPM was initially established in Japan in the late 1970s, only to be introduced to the Western world a decade later. The program's early success in nations such as Australia was limited, but in the late 1990s, a 'westernised' version of TPM was released. The paragraph discusses when and how TPM was introduced to various regions of the world.

Paragraph C

Answer: x. Efficiency through involving all employees
Supporting Sentence: TPM involves directing participating companies and industries to move away from traditional methods of production to more efficient mechanisms.
Keywords: traditional methods, efficient mechanisms.
Keyword Location: Paragraph C
Explanation: TPM entails directing participating firms and industries to shift away from old production processes and toward more efficient procedures. The paragraph emphasises the need of TPM implementation for all employees, not only managers.

Paragraph D

Answer: vii. Implementing TPM
Supporting Sentence: in order to apply the concepts of TPM, a company will have to work through a number of stages.
Keywords: concepts of TPM, work, number of stages.
Keyword Location: Paragraph D
Explanation: A corporation must go through many steps in order to implement TPM ideas. The paragraph discusses the steps of TPM implementation.

Paragraph E

Answer: viii. The guiding principles of TPM
Supporting Sentence: The concept of TPM is built on what are referred to as the three pillars – work area management, risk management and equipment management.
Keywords: work area management, risk management and equipment management.
Keyword Location: Paragraph E
Explanation: The concept of TPM is founded on three pillars: work area management, risk management, and equipment management. The paragraph discusses TPM's three pillars (guiding principles).

Paragraph F

Answer: v. Parallels with a former concept
Supporting Sentence: both processes require a long range outlook, as it may take a year or more to implement and is an ongoing process,
Keywords: long range outlook, ongoing process
Keyword Location: Paragraph F
Explanation: Both procedures need a long-term perspective, since they may take a year or more to execute and are continuing. The paragraph discusses comparisons with TQM.

Paragraph G

Answer: i. Unique focus of TPM
Supporting Sentence: TQM is essentially an output focussed system, whereas TPM is singular in that it looks more at input
Keywords: TPM is singular
Keyword Location: Paragraph G
Explanation: TQM is primarily an output-focused approach, but TPM is unique in that it focuses on input - the equipment utilised and the root causes of actual or potential maintenance problems. The paragraph examines what TPM considers to be priority ('unique focus').

Questions 8 – 11

Complete the flowchart.

Choose NO MORE THAN TWO WORDS from Reading Passage for each answer.

8 Agreement about the _________________ offered by implementing TPM
↓
9 Nomination/ establish of __________
↓
Education and training of workforce
↓
10 Creation of __________
↓
11 Emergence of ____________ to head group

Question: 8

Answer: Potential
Supporting Sentence: TQM is essentially an output focussed system, whereas TPM is singular in that it looks more at input
Keywords: TPM is singular
Keyword Location: Paragraph G
Explanation: TQM is primarily an output-focused approach, but TPM is unique in that it focuses on input - the equipment utilised and the root causes of actual or potential maintenance problems. First, there must be universal consensus inside the organisation that the system has the potential to be effective.

Question:9

Answer: Coordinator
Supporting Sentence: Then a specific person or team needs to be appointed to coordinate the changes required to apply TPM methodologies
Keywords: TPM methodologies
Keyword Location: Paragraph D
Explanation: In paragraph D mentions that a single person or team must be designated to coordinate the modifications needed to implement TPM approaches.

Question:10

Answer: Action teams
Supporting Sentence: Once the coordinator is convinced that the work force is sold on the TPM program and that they understand it and its implications.
Keywords: work force, TPM program, and implications
Keyword Location: Paragraph D
Explanation: In paragraph D mentions once the coordinator is certain. The workforce is committed to and aware of the TPM program's ramifications. Hence Action teams is the right answer.

Question:11

Answer: Team leaders
Supporting Sentence: Usually, the TPM coordinator heads the teams until others become familiar with the process and natural team leaders emerge.
Keywords: natural team leaders
Keyword Location: Paragraph D
Explanation: In paragraph D mentions until others are comfortable with the process and natural team leaders develop, the TPM coordinator often serves as the team leader.

Questions 12 – 15

Label the diagram below using words from the box below. USE EACH CHOICE ONCE ONLY

Write the correct letter A – I in boxes 12 – 15 on your answer sheet

Overall equipment effectiveness
% uptime
$000s / quarter
Machine maintenance costs
% downtime
$000s / month
Employee costs
Wasted resources
Hours spent cleaning maintaining machinery

Question:12

Answer: B- % uptime
Supporting Sentence: initial results for at least the first quarter may actually lead to reduced productivity while changes are put into effect.
Keywords: first quarter, productivity
Keyword Location: Paragraph E
Explanation: In paragraph E, the initial findings, at least for the first quarter, might potentially result in decreased productivity until adjustments are made.

Question:13

Answer: A- Overall equipment effectiveness
Supporting Sentence: The concept of TPM is built on what are referred to as the three pillars – work area management, risk management and equipment management.
Keywords: area management, risk management, and equipment management
Keyword Location: Paragraph E
Explanation: In paragraph E, the three pillars of work. Those are area management, risk management, and equipment management form the foundation of the TPM concept.

Question:14

Answer: C- $000s / quarter
Supporting Sentence: initial results for at least the first quarter may actually lead to reduced productivity while changes are put into effect.
Keywords: first quarter, productivity
Keyword Location: Paragraph E
Explanation: In paragraph E, the initial findings, at least for the first quarter, might potentially result in decreased productivity until adjustments are made.

Question:15

Answer: D-Machine maintenance costs
Supporting Sentence: Using a sample company, statistics collected from a three month period Indicate a substantial reduction in machine maintenance costs, felling by $ 30,000 between 1996 and 1999.
Keywords: three month period, substantial reduction, machine maintenance costs
Keyword Location: Paragraph E
Explanation: In paragraph E, Statistics from a three-month period using a representative firm indicate a significant decline in equipment maintenance expenses, falling by $ 30,000 between 1996 and 1999.

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