TPM – Total Productive Maintenance (Manufacturing) has been developed from the original PM (Preventive Maintenance) concept and methodology. TPM is now rapidly becoming a method applied worldwide and is established as a renowned cultural improvement programme.
TPM drives and delivers world-class performance in production and maintenance and helps close the productivity and quality gap.
TPM is a holistic approach to equipment maintenance that strives to achieve perfect production with little or no breakdowns, no short stoppages or slow running and no defects. It promotes a safe working environment with no accidents. TPM emphasises proactive and preventive maintenance practices to maximise the operational efficiency of equipment and places a strong emphasis on empowering operators to maintain equipment to a high standard.
The implementation of a TPM programme provides an understanding of the principles of TPM and creates a shared responsibility for equipment that encourages greater involvement. Used correctly, TPM is effective in improving productivity by increasing availability, reducing cycle times and achieving zero defects.
The pillar approach is a way of managing change and a rigorous methodology to ensure results and improvements are sustained. The mission of each pillar is to reduce loss with the ultimate aim of elimination of all losses.
How is the ‘Pillar’ implemented?
The pillar follows a structured set of steps aligned with the Plan, Do, Check, Act (PDCA) cycle, which can be implemented for improvement activities of any size or complexity in any organisation.
The pillar builds an understanding and analysis of the different loss types affecting an organisation.
The pillar operates at a strategic level, identifying the criteria for project selection and TPM deployment that will deliver the business objectives.
Why is TPM implemented?
These are three of the main drivers for ‘why do’ TPM.
- Companies increasing reliance and dependency on complicated, high tech, expensive capital equipment. Possibly with no alternative routing if downtime occurs resulting in lost production/profit.
- Because the equipment is increasingly more expensive it pays to recognise what can be done to extend life cycle, through sound TPM methods, rather than a premature costly replacement.
- By improving Overall Equipment Effectiveness (OEE), rather than simple up and downtime measures, is a more refined method of monitoring asset management. Many companies are still unaware of OEE.
To start implementation of TPM senior management need to understand that TPM needs to be part of a long-term culture change programme, not just an initiative for the maintenance department. A TPM structure to support the cultural change needs definition with clear responsibilities and ownership.
What are the benefits?
Companies that support and develop their workforce to understand the importance of operator involvement in maintaining equipment, will quickly see dramatic improvements in production capability and efficiency, resulting in fewer breakdowns, machinery stops and defects with significant bottom-line impact.
In addition, by developing a proactive and preventive maintenance programme, improvements and higher rates of ROI.