Total Productive Maintenance (TPM) Advantages
Regular equipment maintenance is essential to any business using equipment to manufacture, fabricate or assemble products. If the equipment breaks down, the business production grinds to a halt and losses in time and revenue increase.
Total productive maintenance (TPM) can help you avoid these issues. TPM empowers workers to identify and manage potential risks. This results in improved recognition of finding and addressing issues before they become problems and increases equipment efficiency.
What Is Total Productive Maintenance?
The goal of TPM is to help companies streamline the maintenance process and improve performance.
Malfunctioning equipment puts production, workers and the company’s goals under pressure. When equipment fails or is inconsistent in operation, output is impacted and workers are stressed. If the equipment does not work, they will not be able to complete their work.
Total productive maintenance (TPM) works to proactively prevent these situations, streamline the maintenance cycles and get the necessary maintenance done quicker.
Where does Total Productive Maintenance come from?
The total productive maintenance (TPM) approach rests on the 5S lean manufacturing model. This model helps companies keep their workplaces organized and clean.
The 5 S’s are:
- Sort
- Systemize
- Shine
- Standardize
- Sustain
Sorting requires identifying what items and tools get used most frequently, somewhat frequently, less frequently and rarely. They should be organized accordingly so workers can use them all as needed.
Systemization involves giving an item a permanent home. Using the item or tool and then putting it back where it belongs helps all workers and the overall work flow.
Shining is the responsibility of each worker to keep their workspace clean. Regular upkeep is best and make sure not to leave items lying around that can get damaged or cause issues.
Standardizing involves the creation of specific policies and procedures for the maintenance of each piece of equipment. Labeling is important too so every worker can find what they need quickly and easily.
Sustaining is a commitment to each of these 5 steps every day. If this discipline is implemented and enforced, the maintenance process will become more seamless.
Using the 5S concepts as the foundation, there are 8 main pillars of TPM, including:
Autonomous Maintenance – operators take care of routine cleaning and basic upkeep
Planned Maintenance – scheduled maintenance takes place to prevent breakdown
Quality Management – quality defects are identified and handled
Focused Improvement – groups of employees identify areas for continuous improvement
Early Equipment Management – uses practical knowledge to improve the equipment
Training and Education – operators receive the proper training to handle the equipment
Safety, Health, and Environment – the safety of the workplace is safeguarded
Administration – the TPM program gets applied to administrative situations
Each of these pillars contributes to the overall equipment effectiveness (OEE). They also make sure tasks get delegated to specific people. Likewise, the workplace remains a safe and productive place.
Total productive maintenance (TPM) models have the additional benefit of getting the entire team involved. This approach brings everyone from executives to managers to equipment operators on board to focus on maintenance.
Management:
Management needs to get involved in the total productive maintenance model by promoting it as a company policy. They should have a thorough understanding of how it works.
They also need to have the ability to answer employee questions.
Machine Operators:
The machine operators take on the responsibility of keeping them working well. This means knowing about the daily upkeep and having the ability to recognize the first signs of trouble.
Make sure all workers all have training on how to operate the equipment in a safe manner. Tell them how they can report potential problems.
Maintenance Team:
Finally, the maintenance managers should train the operators in the proper care for the equipment. They should also perform more extensive maintenance tasks.
This might include making advanced repairs or performing other maintenance activities.
Boosting Your Equipment’s Effectiveness
One of the most tangible benefits to TPM is more effective equipment. The overall equipment effectiveness (OEE) measurement demonstrates this fact.
Companies that implement TPM see lower amounts of equipment malfunctioning. When equipment starts to not work as well, it quickly gets repaired. As such, the OEE will increase as soon as the company starts using the total productive maintenance model.
Please contact Prosit for assistance with training and implementing total productive maintenance (TPM) for your company or to find out about of our other lean consulting and manufacturing services.