Total Productive Maintenance
Total Productive Maintenance (TPM) is an all-inclusive approach to equipment maintenance that strives to achieve perfect production (zero defects). This means that equipment is expected to have zero breakdowns, slow runs, or defects. TPM also values a safe working environment with a zero accident policy. TPM is a concept with the aim to maximize the productivity of facilities by transferring the responsibility for regular maintenance to employees.
What is your Definition of TPM ?
PILLAR 1 – 5S
TPM starts with 5S. Problems cannot be clearly seen when the work place is unorganized. Cleaning and organizing the workplace helps the team to uncover problems. Making problems visible is the first step of improvement.
PILLAR 2 – JISHU HOZEN
This pillar is geared towards developing operators to be able to take care of small maintenance tasks, thus freeing up the skilled maintenance people to spend time on more value added activity and technical repairs.
PILLAR 3 – KAIZEN
“Kai” means change, and “Zen” means good ( for the better ). Basically Kaizen is for small improvements, but carried out on a continual basis and involve all people in the organization. Kaizen is opposite to big spectacular innovations. Kaizen requires no or little investment. The principle behind is that “a very large number of small improvements are move effective in an organizational environment than a few improvements of large value. This pillar is aimed at reducing losses in the workplace that affect our efficiencies. By using a detailed and thorough procedure we eliminate losses in a systematic method using various Kaizen tools. These activities are not limited to production areas and can be implemented in administrative areas as well.
PILLAR 4 – PLANNED MAINTENANCE
It is aimed to have trouble free machines and equipment producing defect free products for total customer satisfaction. This breaks maintenance down into 4 “families” or groups which was defined earlier.
2. Breakdown Maintenance
3. Corrective Maintenance
Prevention With Planned Maintenance we evolve our efforts from a reactive to a proactive method and use trained maintenance staff to help train the operators to better maintain their equipment.
PILLAR 5 – QUALITY MAINTENANCE
It is aimed towards customer delight through highest quality through defect free manufacturing. Focus is on eliminating non-conformances in a systematic manner, much like Focused Improvement. We gain understanding of what parts of the equipment affect product quality and begin to eliminate current quality concerns, then move to potential quality concerns. Transition is from reactive to proactive (Quality Control to Quality Assurance).
PILLAR 6 – TRAINING
It is aimed to have multi-skilled revitalized employees whose morale is high and who has eager to come to work and perform all required functions effectively and independently. Education is given to operators to upgrade their skill. It is not sufficient know only “Know-How” by they should also learn “Know-why”. By experience they gain, “Know-How” to overcome a problem what to be done. This they do without knowing the root cause of the problem and why they are doing so. Hence it become necessary to train them on knowing “Know-why”. The employees should be trained to achieve the four phases of skill. The goal is to create a factory full of experts.
PILLAR 7 – OFFICE TPM
Office TPM should be started after activating four other pillars of TPM (JH, KK, QM, PM). Office TPM must be followed to improve productivity, efficiency in the administrative functions and identify and eliminate losses. This includes analyzing processes and procedures towards increased office automation. Office TPM addresses twelve major losses.
Technical benefits such as…
- productivity improvement of more than 35%
- increased equipment effectiveness from 50-70% to 80-90%
- unplanned downtime (breakdown & minor stoppages, etc.) reduced by about 80%
- reduced quality defects by up to 50%
- scrap reductions of approximately 65%
Social benefits such as…
- motivated workers committed to improvement
- goal oriented efficient teams
- pro-active, solution oriented thinking and acting
- safe and stable operating environment