Overview

 

Overview

 

TPM stands for

 Total

  Productive

 Maintenance

It signifies the active participation of all employees within the factory, from the ground level up to management.

Total Productive Maintenance (TPM) started in the heart of Japanese manufacturing and has grown into a vital approach for maintaining plants. As more factories implement TPM strategies, they have amassed a rich pool of experiences and insights.

TPM is all about teamwork and getting everyone on board, especially those in production, maintenance, and engineering. The goal here is to boost our productivity by building a collective dedication to achieving Zero Breakdowns, Zero Defects, and Zero Accidents. Each person involved in the manufacturing process plays an essential part in making this vision a reality.

It consists of six major activities,

1. Elimination of six major losses identified by the production, maintenance, and manufacturing technology teams.

2. Scheduled upkeep is backed by the maintenance team.

3. Self-directed maintenance backed by the production department.

4. Preventive engineering is primarily conducted by the new product development team.

5. Proposal for a product that is simple to manufacture, developed by the product design team.

6. Education and training are essential to support the events organized by the administration unit.

The Elimination of six big losses

To effectively address all 16 losses, it's essential to consistently monitor overall equipment effectiveness (OEE) by calculating three key factors: availability, performance, and quality. Regular OEE calculations are crucial for identifying and eliminating daily losses on the shop floor.

To effectively address the Gemba downtime occurring during our 8 hours of production, we must first identify all contributing factors. After capturing these factors, we should categorize them according to the 16 loss types. This will allow us to pinpoint which downtime aligns with each specific loss category. Once we've organized this information, we can proceed to analyze the losses and develop targeted solutions for their elimination.

Planned Maintenance

This system is primarily acknowledged by the maintenance unit. Positive feedback can be anticipated, provided that the maintenance staff put in a dedicated and prompt effort. A strong commitment from the maintenance team is essential for the successful implementation of the TPM system in the Gemba area. There are four key areas that need attention:

1.Decrease inconsistency of components life

     2.Restore deteriorated components periodically

     3.Extend components life

     4.Forecast components life

Many factories utilize a seven-step program to implement planned maintenance, which often intersects with the activities of operators. As a result of these initiatives, the lifespan of components has been significantly extended, and a structured approach to periodic (time-based) maintenance can be identified.

To ensure the longevity of critical machine components, it is essential to monitor their condition and replace parts before they fail. By implementing a predictive maintenance strategy, we can maximize the operational lifespan of the machinery.

Autonomous Maintenance

Operators, with the support of maintenance crew members, execute their tasks. These operators are well-trained in a comprehensive seven-step process designed to achieve the following key objectives:

1.Ensure the fundamental equipment conditions are established by performing cleaning, lubrication, inspection, tightening, and adjustments.

2.Please ensure that you adhere to the machine's usage conditions.

3.Conduct a comprehensive inspection to revitalize damaged components.

4.Managed routine maintenance independently under the operator's supervision.

The maintenance tasks outlined above are carried out by the operators themselves, adhering to the guidelines they’ve set. This approach is referred to as autonomous maintenance.

The coordination between the production and maintenance departments is crucial. Developing an Autonomous Maintenance System typically takes a minimum of three to four years. This extensive, factory-wide effort engages all employees and can lead to significant improvements and profits.

Preventive Engineering

Several challenges arise during the commissioning phase of a new production line that need to be addressed promptly. Effective equipment management entails a series of well-planned corrective actions aimed at transitioning operations into commercial production as quickly as possible.

To effectively address the challenges at hand, it's essential to tackle the root causes of difficulties not only during the current commissioning period but also during the earlier phases, when various responsibilities in plant engineering are undertaken. This includes aspects such as theoretical design, initial design, procurement and fabrication, installation, test runs, and the overall commissioning and turnover process.

The hard work in this area has evolved into what we now call preventive engineering. This encompasses all preventive activities carried out at every stage of the process, from plant engineering and procurement to construction and ultimately turnover.

Easy to manufacture product design

In light of the ever-shortening life cycles of products, it’s crucial to meet the increasing demands of consumers regarding attractiveness, design, quality, and price. This approach is essential for maintaining competitiveness in the global marketplace.

As a result, the challenges in manufacturing that were once difficult to address through gemba efforts alone can now be more easily resolved by integrating comfort in manufacturing and quality assurance during the product design phase. There is still limited experience in this area, and it is expected to play an increasingly significant role in Total Productive Maintenance (TPM).

Training and education

All employees in the organization must receive comprehensive training for all aspects of Total Productive Maintenance (TPM). Understanding the significance of regularly practicing TPM, the effort required to excel in this area, and the necessary skills to succeed is crucial. Our current internal capabilities alone may not be sufficient to reach TPM objectives. Therefore, every employee should take initiative to enhance their knowledge and skills by seizing every opportunity for learning and development in these essential areas.

The operator's training in the seven-step approach to autonomous maintenance plays a crucial role in successfully implementing a Total Productive Maintenance (TPM) framework within the production department.

•  TPM means Total Productive Maintenance.

•   It is a effective tool and it starts from the shop floor.

•   Implementation process is the key success of TPM.

•   Changing the machine, changing the people and changing the environment.

•   TPM will improve the business.

Manager Model Machine:

•   Need to identify manager model machine.

•   The machine identified as the least effective, most critical, or the bottleneck within the system will be designated as the manager model machine.

Data's need to collect for the bench marking:

•   All parameters for the past year, including Breakdown rates, Defect occurrences, Accident counts, Mean Time To Failure (MTTF), Mean Time Between Failures (MTBF), Mean Time To Repair (MTTR), and Overall Equipment Effectiveness (OEE).

•   I need to analyze the machine using data from the past year, as this will serve as the   benchmark.

•   Please create the PQCDSM target sheet for the Manager Model Machine.

•   A 30% improvement is required in the Manager Model Machine within the next four   and a half months.

•   The 4.5-month target is a scientifically validated goal.

8 Pillars in TPM

1.   Kobetsu Kaizen (Focussed Improvement).
2.   Jishu Hozen (Autonomous Maintenance).
3.   Kaikaku Kaizen (Planned Maintenance).
4.   Hinshitsu Hozen (Quality Maintenance).
5.   Development Management.
6.   Education & Training.
7.   Office TPM.
8.   Safety Health & Environment.

KK Pillar

•   This pillar primarily addresses time and cost, along with the parameters associated with both.

•   OEE calculation.

•   OLE calculation.

•   Machine productivity.

•   Manufacturing lead time reduction.

JH Pillar

•    It is also called front line Maintenance or Autonomous Maintenance.

•    We need to pinpoint the specific area or tasks within the maintenance activities that will be handled by the operator, CLITOA.

•    Cleaning.

•    Lubricating.

•    Inspecting.

•    Tightening.

•    Operating.

•    Adjusting.

•    This pillar is value added to the operator.

PM Pillar

•    Need to do radical changes in the machine.

•    Need to do specialized maintenance.

•    Need to do TBM and CBM.

•    Achieve zero break down.

QM Pillar

•    Aim to achieve zero defect.

•    Need to satisfy customer requirement.

DM Pillar

•    New product development and new product development cost.

•    Primary responsible is introducing PPE.

•    Product, Process and Equipment(PPE).

•    Productivity improvement through design enhancement.

•   If there are any design issues with the current product, process, or equipment, this pillar will focus on addressing those concerns.

E & T Pillar

•    The main focus is to enhance the knowledge and skill sets of individuals.

•    The number of people involved is not enough; we require skilled individuals with expertise relevant to the process.

OTPM

•    All supporting functions are grouped into one pillar called Office TPM Pillar.

•    HR, Finance, IT, SCM, S&M, R&D.

•    Inside the plant, seven pillars hold responsibility, while OTPM oversees operations outside the plant.

•    All management losses need to be eliminate by this pillar.

•    Machine performance is not achieved due to non-technical reasons is called Management Loss.

•    Overall lead time reduction.

•    Procurement lead time reduction.

•    Delivery lead time reduction.

SHE Pillar

•    Identify the hazardous wastages generated by the machine and eliminate completely.

•    Identify the near miss and accidents and eliminate completely.

•    Achieve zero accident.

   The instant you interact with the machine, take a moment to understand its operation and consider how you can help maintain its original condition.