Total Productive Maintenance is a concept of lean manufacturing and majority applicable to all sectors. TPM concept is majority useful for increasing asset reliability towards desired performance. One of the goals of an organization is to utilize assets (equipment, machines) effectively. To utilize the entire asset and its caring is very important just like a mother care for her child & continuously makes efforts to make it strong in all direction. A similar concept will apply to equipment & machines. So in short, to cut the story long TPM is all about maintaining assets in such a way to utilize asset effectively.
Content
- History of TPM
- Objective of TPM Implementation.
- Eight Pillars of TPM
- Understand the life cycle of asset.
- Starting stage of TPM implementation.
- Understand the role of production, maintenance and quality.
- Understand the most important measuring parameters used for TPM Implementation.
History of TPM
Father of TPM: – Seiichi Nakajima
Developed in 1969.
JIPM (Japan Institute of Plant Maintenance) was established in 1969 and is a its non-profit organization. The main objective of JIPM is to provide services to factory or plant management, maintenance engineers, and plant engineers.
Objective for TPM Implementation.
- Improving equipment (asset) productivity. (Overall Equipment Effectiveness)
- Zero Accident
- Zero Breakdown
- Zero Changeover or small stops
- Zero Defects.
As per the above-mentioned objectives, the very important and ultimate objective of TPM is to maximize equipment effectiveness with the help of avoiding accidents, breakdowns, set-up, changeovers, and defects. From a financial point of view improving equipment effectiveness with the help of reducing equipment maintenance costs.
TPM Pillars
- Jishu Hozen (Autonomous Maintenance): – Jishu Hozen pillar is a very important part for increasing or maintaining machine conditions and its life span. Autonomous maintenance pillar mainly focused on to defining ownership of machine, tag management system, machine operator’s involving into maintenance activities & CLIT sheet management.
- Focused Improvement: – Focused improvement is also known as continuous improvement as well as kobetsu kaizen. Focused improvement pillar mainly involves 16 different types of losses that happened during operational processes. Mainly Kobetsu kaizen pillar systematically measure, analyze and minimize losses of operational processes.
- Preventive Maintenance: – Preventive maintenance is pre-planned maintenance activity that periodically plan for machine maintenance. In preventive maintenance, mainly team focused to routine check-up of machine, identify machine faults, conditions of machine parts etc.
- Quality Management: – Quality management pillar focused on to defect generation based on machine faults. For quality management data analysis perspective process capability study, 7 QC tools, Defect analysis and many more.
- Early Equipment Management: – Early equipment management is mainly focused on spare parts management, ensure its timely availability as well as its lifecycle.
- Office TPM: – office TPM involves, office 5 s, smoothening of administration activities, office inventory management, office layout improvement and many more.
- Training & Development: – In training & development pillar each every staff members and workers involvement is very important. In TPM implementation structurally plan detail training on each individual pillar as well as practical guidelines of implementation.
- Environment Health & Safety: – EHS is most essential pillar for operational activities that involves identifying unsafe conditions, conducting safety audits, environment compliances, waste management & Staff as well as workers health etc.
Understand the life cycle of equipment or asset
Basically life cycle of equipment or asset are divided into four stages as per mention below.
- Planning stage: – Planning to procure asset.
- Procurement stage: – Procure the asset & Install it.
- Operation & Maintenance stage: – Operate & Maintain asset.
- Disposal stage: – Dispose of the asset.
When any organization procures new equipment or machines, a certain month or year’s life cycle will be decided as per design consideration. If we analyze the financial point of view value of equipment will reduce day by day due to considering depreciation. For improving asset productivity, asset reliability is very important for equipment performance, and equipment available time for production. Out of four stages, each and every asset spends too much time in 3rd stage. So the entire TPM concept is all about operating and maintaining assets & its performance.
What is the starting stage of TPM Implementation?
When any organization is interested in implementing a total productive maintenance tool, the very first step is to start with implementing 6 S (5 S) methodology. Let’s understand 6 s is a very fundamental & ground-level tool before implementing TPM or lean manufacturing. Review below attached 6 S methodology article for more technical information.
Understanding the role of the Production, Maintenance and quality department of any organization.
Majority of manufacturing industries three departments play a vital role in improving business performance such as production, maintenance, and quality. The main role of production is to produce products as per customer requirements with the help of available resources like machines, equipment and other assets. The maintenance department is responsible for ensuring machines, equipment & other assets are available for producing products without faulty or breakdown conditions. The quality department ensures product quality that can be produced with the help of different assets, They are also responsible for identifying errors asset-related or human-related.
What are the measuring parameters to be used for implementing the TPM tool?
There are several parameters used for process measurement during TPM implementation. Before going into much more detail understanding, try to understand effective data collection is very much required for correct analysis for improvement. The TPM journey starts with data collection and its proper analysis because the area of improvement must be visible in the data. Review below attached measuring parameters that can be useful during TPM implementation.
- OEE (Overall Equipment Effectiveness): – OEE is basically equipment performance measurement parameters & measure equipment output on a timely basis. Its calculation depends on three parameters such as availability, performance, and quality.
- MTBF (Mean time between failure): – It is calculated based on the average gap between two consecutive breakdowns.
- MTTR (Mean time to repair): -MTTR calculated based on the average breakdown time of equipment.
- Breakdown / Preventive Maintenance Hours
- Nos of kaizen collection / Nos of Breakthrough improvements done.
- Nos of near miss / Accidents / Unsafe act / Un-safe conditions.
- First time yield / Rolled throughput yield.
- 6 S & TPM audit score.
Really, I liked your article a lot as this article provided very clear information. I have trained from one of the institutes, but they don’t explain the way this article is explained.
Really, I liked your article. I have trained from one of the institutes, but they don’t explain the way this article is explained.