Evolution

Evolution

The term Total Productive Maintenance (TPM) stems from the principles of productive maintenance that were first developed in the United States in 1971. This concept was later promoted by the Japan Institute of Plant Maintenance (JIPM). Initially, its implementation in small-scale industries did not lead to significant success. As a result, these industries were actively searching for effective operational strategies to remain competitive in the market.

In 1981, a seven-step program for implementing an operator's routine maintenance system was introduced at Tokai Rubber Industries, yielding significant benefits. Since then, the adoption of the Total Productive Maintenance (TPM) system has steadily increased across various factories. This system effectively enhances operational conditions in existing plants while also improving employees' knowledge and skills.

Japanese manufacturers have encountered significant challenges in their operations, notably due to unpredictable fluctuations in oil prices and current exchange rates. In light of these hurdles, an increasing number of companies are turning to Total Productive Maintenance (TPM) as a comprehensive approach. Today, TPM is often viewed as an abbreviation for Total Production Management, encompassing not just plant maintenance but also plant engineering and product design.

The concept of Total Productive Maintenance (TPM) originated from the creative approaches of preventive and productive maintenance. In 1971, Nippon Denso Co., Ltd. was the first to announce and successfully implement TPM in Japan. Their remarkable efforts earned them the Japan Institute of Plant Maintenance’s (JIPM) PM Excellent Plant Award, marking a significant milestone for TPM in the country. Over time, the practice of TPM has gradually expanded across the globe, establishing itself as a prominent cultural enhancement program.

The first notable instance of Total Productive Maintenance (TPM) in Europe was executed by Volvo in Ghent, Belgium, where they earned the PM award for their outstanding work in the paint shop. This achievement quickly inspired other European automotive manufacturers in the early 1990s to enhance their productivity and quality, aiming to catch up with their Japanese competitors.

Since the inception of the JIPM TPM awards, more than 3,000 organizations have been recognized for their achievements.

                                How Maintenance Evolved in Japan

 

                1950             1960             1970              1980               1990                    

Breakdown Maintenance

Preventive Maintenance

(1957) Corrective Maintenance

            

(1960) Maintenance Prevention

                            

(1971) Total Productive                                                                     Maintenance(TPM)

                                                    

Time Based Period                                   Condition Based Period

The production operators were engaged in producing components by operating various machines, while the maintenance crew was tied up with significant tasks, including replacing or repairing major machine parts. This created a challenge for the maintenance crew, as they required additional personnel to keep all the machines running smoothly. Recognizing this issue, the upper management decided that operators would handle minor maintenance tasks, allowing the maintenance crew to focus exclusively on more critical maintenance activities.

Some of the challenges currently faced by existing machines have been analyzed, leading to improvements being integrated into new machines, a concept known as preventive maintenance. By combining preventive maintenance with maintenance prevention, we can achieve more productive maintenance overall.

Operators should thoroughly study the functions of the machines and their components. By taking on minor maintenance tasks, they can earn the designation of autonomous maintenance.

Maintenance:

Keeping the equipment in optimal condition is essential, ideally exceeding the original specifications of its parts.

Types of Maintenance

It can be classified into four types,

1.Breakdown Maintenance

2.Preventive Maintenance

3.Corrective Maintenance

4.Maintenance prevention

Breakdown Maintenance:

The replacement of machine parts occurs only when they have completely failed and are no longer operational.

Preventive Maintenance:

Maintenance is conducted at set intervals to assess the timeframe and condition of machine components either before failures occur or prior to any actual breakdowns. This process can be categorized into two main types namely periodic maintenance and predictive maintenance.

Periodic Maintenance:

Time-based maintenance refers to the practice of replacing specific machine parts after a set period, such as every 15, 30, or 90 days, to prevent breakdowns.

Predictive Maintenance:

Condition-based maintenance, often referred to as CBM, relies on observing signs such as unusual noises, distinct smells, or visible and tactile cues from the equipment to predict potential breakdowns before they occur.

Corrective Maintenance:

The process involves analyzing the current machinery that has design issues. A detailed assessment is conducted to identify the weak components, which are then re-engineered to enhance the equipment’s maintainability. This results in improved reliability and helps to prevent part failures.

Maintenance Prevention:

When creating new machines, we thoroughly analyze the challenges faced by existing models, focusing on quality, safety, and ease of maintenance. This comprehensive approach allows us to incorporate innovative ideas and enhancements into the new equipment, effectively reducing the risk of breakdowns.