Focused Improvement (Kobetsu Kaizen) in TPM: Eliminate Losses & Boost Productivity

🟢 FOCUSED IMPROVEMENT (KOBETSU KAIZEN) IN TPM: ELIMINATE LOSSES FAST

Focused Improvement in TPM, also known as Kobetsu Kaizen, is the backbone of any high-performing maintenance culture. It empowers teams to systematically identify, analyze, and eliminate chronic losses that impact equipment, processes, and productivity. The goal? Drive continuous improvement and achieve a world-class manufacturing environment.

🔍 Understanding the Power of Kobetsu Kaizen

“Kobetsu” means “specific” and “Kaizen” means “continuous improvement.” This powerful TPM pillar zeroes in on recurring problems — the kind that eat away at your efficiency, product quality, and machine uptime.

Unlike general problem-solving, Focused Improvement uses data and team-based brainstorming to remove the root causes of issues, not just treat the symptoms.

8 Pillars of TPM:

1. Autonomous Maintenance – Operators take care of routine maintenance. – Read More

2. Planned Maintenance – Scheduled maintenance to prevent breakdowns. – Read More

3. Quality Maintenance – Eliminate defects at the source. – Read More

4. Focused Improvement – Small teams improve efficiency. – Read More

5. Early Equipment Management – Design equipment for easy use and maintenance. – Read More

6. Training & Education – Skill development for all staff. – Read More

7. Safety, Health & Environment – Ensure a safe, clean workplace. – Read More

8. Office TPM – Apply TPM in admin and support areas. – Read More

✅ Key Benefits for Your Workplace

• Identify and eliminate chronic losses and inefficiencies

• Improve equipment availability and reliability

• Boost OEE (Overall Equipment Effectiveness)

• Empower cross-functional teams to solve real problems

• Promote a data-driven culture of continuous improvement

• Reduce cost per unit and increase profit margins

• Improve employee ownership and morale

• Build a scalable improvement system across all departments

⚙️ Common Losses Focused Improvement Tackles – Focused Improvement in TPM

1. Equipment breakdowns

2. Setup and adjustment time

3. Minor stoppages and idling

4. Speed loss and slow cycles

5. Quality defects and rework

6. Startup rejects during shift changes

7. Wasted energy, material, and motion

🛠 How to Apply Focused Improvement in TPM

1. Identify chronic issues using equipment loss data

2. Form a Kaizen team with operators, technicians, and engineers

3. Analyze root causes using tools like 5 Whys and Fishbone Diagrams

4. Develop and test solutions using the PDCA cycle

5. Implement countermeasures and monitor effectiveness

6. Standardize improvements and train others to sustain the gains

📈 Real-Life Example

Problem: A bottling line faces frequent micro-stops due to label misalignment.

Kaizen Action: A cross-functional team uses root cause analysis and discovers vibration is loosening the sensor mount. A bracket is added to secure the sensor.

Result: Micro-stoppages drop by 70%, recovering over 15 hours/month in lost production time.

🧰 Common Tools Used in Kobetsu Kaizen

• 5 Whys

• Pareto Chart

• Fishbone Diagram (Ishikawa)

• Why-Why Analysis

• PDCA (Plan-Do-Check-Act)

• Time Loss Analysis

• Spaghetti Diagram (for motion waste)

📚 Additional Learning

Want to dive deeper into Total Productive Maintenance? Explore the full list of TPM pillars in our article:
👉 The 8 Pillars of TPM Explained

Interested in workplace organization?
👉 Read: What is 5S Lean Management

🖼 Visual Example – Focused Improvement in TPM

A real example of eliminating speed loss through cross-functional teamwork.

✅ Top Interview Questions & Answers on Focused Improvement (Kobetsu Kaizen)

1. What is Focused Improvement (Kobetsu Kaizen) in TPM?
Answer:
Focused Improvement, also known as Kobetsu Kaizen, is a key TPM pillar that focuses on identifying and eliminating chronic losses in manufacturing processes.

The goal is to improve equipment efficiency and productivity by solving specific problems through cross-functional teamwork and structured problem-solving tools like 5 Whys, Fishbone Diagrams, and Pareto Analysis.

2. What are the typical losses targeted in Focused Improvement?
Answer:
The seven major losses targeted include:

1. Equipment breakdowns

2. Setup and adjustment losses

3. Minor stops

4. Speed losses

5. Quality defects

6. Startup rejects

7. Energy and resource waste

3. How does Focused Improvement help improve OEE?
Answer:
Focused Improvement directly enhances OEE (Overall Equipment Effectiveness) by reducing downtime (Availability), minimizing performance losses (Performance), and eliminating defects (Quality).

By systematically addressing root causes of inefficiencies, teams can significantly boost equipment reliability and output.

4. What tools are commonly used in a Focused Improvement activity?
Answer:

• Pareto Chart

• 5 Whys Analysis

• Fishbone Diagram (Ishikawa)

• PDCA Cycle (Plan-Do-Check-Act)

• FMEA (Failure Mode and Effects Analysis)

• Time Loss Analysis

• Root Cause Analysis (RCA)

5. Can you give an example of a Focused Improvement project you’ve been part of?

Answer: Yes, in my previous role, we faced frequent minor stops on a packaging line. Using Pareto analysis, we found the main issue was a misaligned sensor.

A cross-functional team used 5 Why analysis and discovered vibrations caused the misalignment. We added a bracket for support, reducing minor stops by 80% and saving 2 hours/day.

6. How is Focused Improvement different from Autonomous Maintenance?

Answer: Autonomous Maintenance empowers operators to take care of basic equipment maintenance tasks like cleaning, inspection, and lubrication.

In contrast, Focused Improvement involves structured team efforts to analyze and eliminate chronic or recurring equipment or process problems that affect performance or quality.

7. Why is cross-functional teamwork important in Kobetsu Kaizen?

Answer: Cross-functional teams bring diverse perspectives—operators know the process, maintenance understands the machines, and quality can trace defect trends.

This diversity leads to more effective root cause analysis and sustainable solutions that are accepted and implemented across departments.

8. What are the key phases of a Focused Improvement activity?
Answer:

1. Identify the problem

2. Form a cross-functional team

3. Collect and analyze data

4. Determine root causes

5. Develop and implement solutions

6. Monitor effectiveness

7. Standardize successful practices

9. What is the role of data in Focused Improvement?
Answer:
Data is essential. It helps in identifying the most frequent or costly losses (e.g., using Pareto analysis), validating root causes, and measuring the effectiveness of solutions.

Without data, improvements are based on assumptions rather than facts.

10. How do you sustain improvements made through Kobetsu Kaizen?

Answer: Sustainability comes through standardization (updating SOPs), training, visual controls, ongoing audits, and feedback loops.

Also, making improvements part of daily routines and performance KPIs helps embed them into the culture.

🏁 Final Thoughts

Focused Improvement in TPM isn’t just a tool — it’s a mindset. By engaging your team, using data, and attacking chronic losses head-on, you’ll unlock hidden capacity, reduce waste, and build a resilient operation ready for long-term success.

👨‍🏫 Want to Learn More?

Explore our TPM Certification programs at SkillUpCertification.com to deepen your expertise and lead the charge in operational excellence.