Why You Need Total Productive Maintenance (TPM)?

Do you experience machine breakdowns on a regular basis? Are you manufacturing products that aren’t made consistently on equipment and machinery? Do you have to remake items because they fail quality inspections? If you answered yes to any of these questions, this is a clear sign that you could benefit from implementing an efficient TPM process.

Like you, many companies desire processes that improve the quality of products, reduce the costs of production, and increase productivity – in order to become a reliable leader in the industry. With Total Productive Maintenance (TPM), you can learn ways to decrease lost production time, reduce defects, and lower material waste build-up.

An introduction to TPM

The origins of TPM go back over 70+ years and are often considered as an innovative Japanese concept. The overall goal of a TPM program is to improve the integrity of production and the quality of products through regular equipment maintenance. Just think of TPM as preventative medicine for your machines and equipment – one that helps your business increase production processes.

Preventative maintenance is a strategy that focuses on routinely checking machinery and equipment – before they break down or cause expensive, unnecessary issues.

In order to implement a successful TPM process, your workplace needs to be organized and clean. If you thought this would include utilizing some 5S workplace, you’re correct.  A successful 5S process is an important pre-requisite to have under your belt prior to diving into TPM.

If you need help implementing 5S, visit here for expert advice and direction.

Oftentimes machine or equipment maintenance is considered the less desirable and difficult lean manufacturing tool; however it is worth the time and investment in the long run.

So how does TPM work?

With TPM implemented in your workplace, running equipment and machines until they break down is part of the past. Preventative maintenance allows your organization to focus more on production time, instead of wasting time on emergency and unscheduled repairs.

In order to improve the overall equipment effectiveness (OEE) and eliminate productive waste, create small multidisciplinary teams to measure processes. OEE is part of the improvement step of process worth management and takes into account all losses – from availability, performance, and quality.

Tracking and collecting the OEE data is an integral component of the TPM process, as each collection aims to stop all defects, breakdowns, and stops.

The three questions to measure OEE are:

Availability – What is the percentage of time that a piece of equipment or a particular process is available for production, without downtime from breakdowns?

Performance – How well is the production process performing? Has the speed or efficiency of the equipment changed?

Quality – How many products were of good quality? Has the defect-rate of produce goods increased or decreased?

Make improvements based on your findings and start the TPM pillars for success.

What are the eight pillars or parts of TPM?

  1. Autonomous Maintenance: Places the responsibility for maintenance, cleaning, and inspection on the operators of machinery and equipment.
  2. Development Methods: Get team leaders and managers together to collect information from operators to predict or prioritize preventative maintenance.
  3. Quality Maintenance: Operators and team leaders apply root cause analysis to prevent recurring defects from occurring with machines and products.
  4. Process Worth Management: Implement small groups of employees to proactively work together to find any needed improvements in equipment.
  5. Improvement Stages of New Equipment: Based on maintenance reports and equipment lifecycles, TPM knowledge is used for the enhancement and redesign of new equipment.
  6. Education & Training: Operators, managers, and maintenance personnel are trained to recognize proactive and preventative resolutions.
  7. Safe and Healthy Workplace: Eliminate unsafe risks and focus on an accident-free workplace through a successful TPM process.
  8. Administrative Work: Remove unwanted waste beyond the plant floor by making improvements with processes throughout the workplace.

By utilizing TPM processes, you will reach the following S.M.A.R.T goals:

  • Save money by equipment and products meeting company standards.
  • Manage a clean and organized workplace.
  • Avoid product, material, and time waste in a rapidly changing economic environment.
  • Reduce accidents and repairs.
  • Teamwork and confidence among your employees through TPM processes.

Through the total participation of your workplace, TPM focuses on cultivating the overall success of your facility. Strive to get your entire company on board and start recognizing problems, finding solutions, and preventing breakdowns of equipment or machinery.

If you’re interested in learning more about TPM or need onsite support, contact David Visco at 978-842-4610 or email him at David.Visco@The5SStore.com.

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