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