Getting operators involved in maintaining their own
equipment, and emphasizing proactive and preventive maintenance will lay a
foundation for improved production (fewer breakdowns, stops, and defects).
WHAT IS TPM?
TPM (Total Productive Maintenance) is a holistic approach
to equipment maintenance that strives to achieve perfect production:
·
No Breakdowns
·
No Small Stops or Slow Running
·
No Defects
In addition it values a safe working environment:
·
No Accidents
TPM emphasizes proactive and preventative maintenance to
maximize the operational efficiency of equipment. It blurs the distinction
between the roles of production and maintenance by placing a strong emphasis on
empowering operators to help maintain their equipment.
The implementation of a TPM program creates a shared
responsibility for equipment that encourages greater involvement by plant floor
workers. In the right environment this can be very effective in improving
productivity (increasing up time, reducing cycle times, and eliminating
defects).
TRADITIONAL TPM PILLARS
The traditional approach to TPM was developed in the 1960s
and consists of 5S as a foundation and eight supporting activities (sometimes
referred to as pillars).
The
traditional TPM model consists of a 5S foundation (Sort, Set in Order, Shine,
Standardize, and Sustain) and eight supporting pillars.
The eight pillars of TPM are mostly focused on proactive
and preventative techniques for improving equipment reliability.
Pillar |
What
Is It? |
How Does It Help? |
Autonomous
Maintenance |
Places
responsibility for routine maintenance, such as cleaning, lubricating, and
inspection, in the hands of operators. |
· Gives operators greater “ownership” of their equipment. · Increases operators’ knowledge of their equipment. · Ensures equipment is well-cleaned and lubricated. · Identifies emergent issues before they become failures. · Frees maintenance personnel for higher-level tasks. |
Planned Maintenance |
Schedules
maintenance tasks based on predicted and/or measured failure rates. |
· Significantly reduces instances of unplanned stop time. · Enables most maintenance to be planned for times when equipment is not
scheduled for production. · Reduces inventory through better control of wear-prone and
failure-prone parts. |
Quality Maintenance |
Design error
detection and prevention into production processes. Apply Root Cause Analysis
to eliminate recurring sources of quality defects. |
· Specifically targets quality issues with improvement projects focused
on removing root sources of defects. · Reduces number of defects. · Reduces cost by catching defects early (it is expensive and unreliable
to find defects through inspection). |
Focused Improvement |
Have small groups of
employees work together proactively to achieve regular, incremental
improvements in equipment operation. |
· Recurring problems are identified and resolved by cross-functional
teams. · Combines the collective talents of a company to create an engine for
continuous improvement. |
Early Equipment
Management |
Directs practical
knowledge and understanding of manufacturing equipment gained through TPM
towards improving the design of new equipment. |
· New equipment reaches planned performance levels much faster due to
fewer startup issues. · Maintenance is simpler and more robust due to practical review and
employee involvement prior to installation. |
Training and
Education |
Fill in knowledge
gaps necessary to achieve TPM goals. Applies to operators, maintenance
personnel and managers. |
· Operators develop skills to routinely maintain equipment and identify
emerging problems. · Maintenance personnel learn techniques for proactive and preventative
maintenance. · Managers are trained on TPM principles as well as on employee coaching
and development. |
Safety, Health,
Environment |
Maintain a safe and
healthy working environment. |
· Eliminates potential health and safety risks, resulting in a safer
workplace. · Specifically targets the goal of an accident-free workplace. |
TPM in
Administration |
Apply TPM techniques
to administrative functions. |
· Extends TPM benefits beyond the plant floor by addressing waste in
administrative functions. · Supports production through improved administrative operations (e.g.,
order processing, procurement, and scheduling). |
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