What is TPM?
What is TPM?
Before TPM, maintenance and asset management used to be a monitor and fix-it exercise. For example, if a piece of equipment in a furniture factory went down, the next step is to call the maintenance team to fix the machine. The operators would stand around waiting or maybe would go and have a cup of coffee.
Plants that practice Total Productive Management (TPM) today empower employees not only to identify production problems but also to take corrective actions to prevent that downtime from happening again.
Raffy Pefianco of RMP Consultancy conducting TPM Training at BAG Electronics, Inc.
Time-based preventive maintenance replaced this traditional role as the value of preventing machinery breakdowns became obvious, much the same way as quality management focused on prevention rather than cure of quality problems. Unfortunately, along with this realization, too often an adversarial relationship sprang up between maintenance and production characterized by an “us vs. them” mentality.
Production supervisors and workers felt that if maintenance personnel did their job, there would be no breakdowns. On the other hand, maintenance people almost universally thought that the machine operators were abusing the machines and causing work stoppages through their negligence. Actually, both parties were right to a degree.
Raffy Pefianco of RMP Consultancy conducting TPM Training at Lexmark in Cebu
Today, Total Productive Maintenance (TPM) reflects a shift in the old paradigm. Implementation of a successful TPM program requires machinery to be maintained at its top running efficiency as an essential part of maintaining quality, productivity and safety. It is also recognizes that the efforts to achieve this must be a part of a continuous improvement process throughout the company.
Furthermore, it is a vital part of striving toward Lean Manufacturing because fixing a broken piece of machinery or equipment is definitely not a value-added activity and adds unnecessary cost to a product or service. Thus, TPM involves teams of operators caring for their machines and working with maintenance personnel and company management towards no machine-related production delays of any kind.
Three Goals of TPM
The first goal of an effective TPM program is to achieve zero breakdowns, zero defects and zero accidents in all of a company’s processing areas. A successful TPM program will ensure that all machinery and equipment function without disruptions to production related to mechanical problems, product quality problems or worker accidents all causes of waste and lower productivity.
The second goal is to establish a comprehensive maintenance scheme that will achieve the first goal for the life of the equipment. After all, a lofty objective such as the one spelled out above must have a plan in place to make it happen.
The third goal is to involve and empower all employees who specify, design, maintain or use the machinery to implement the plan that has been created.
Unfortunately, many plants, large and small, still consider maintenance as a costly overhead expense. But it is ultimately less costly to pay now through the development of a comprehensive preventive maintenance program than to pay later when a machine malfunction derails your ability to efficiently produce quality products on time.
Repair costs and the related costs of lower productivity, quality problems and accidents are all unnecessary and avoidable. That’s why the goals of TPM are to avoid these costs in a continuous process of prevention and improvement.
The Benefits of TPM
Total Productive Maintenance (TPM) seeks to engage all levels and functions in an organization to maximize the overall effectiveness of production equipment. This method further tunes up existing processes and equipment by reducing mistakes and accidents. Whereas maintenance departments are the traditional center of preventive maintenance programs, TPM seeks to involve workers in all departments and levels, from the plant-floor to senior executives, to ensure effective equipment operation.
Autonomous maintenance, a key aspect of TPM, trains and focuses workers to take care of the equipment and machines with which they work. TPM addresses the entire production system lifecycle and builds a solid, plant-floor based system to prevent accidents, defects, and breakdowns.
The goal is the total elimination of all losses, including breakdowns, equipment setup and adjustment losses, idling and minor stoppages, reduced speed, defects and rework, spills and process upset conditions, and startup and yield losses. The ultimate goals of TPM are zero equipment breakdowns and zero product defects, which lead to improved utilization of production assets and plant capacity.
TPM Seminar Outline
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