Total Productive Maintenance is the strategy used to maximize the effectiveness of the asset, equipment or machinery by involving all the departments in an organization for maintaining the assets. TPM focusses on achieving the goal “Perfect Production” by eliminating the losses such as Availability Loss, Performance loss and quality loss happening with critical equipment or assets
Total Productive Maintenance takes the organization towards the cultural shift and make everyone in an organization responsible for Maximizing the Asset Effectiveness.
5S of Total Productive Maintenance
Total Productive Maintenance principles are developed based on the 5S model such as
- Sort
- Straighten
- Shine
- Standard
- Sustain
Sort
Keep the required resources such as Tools, Equipment etc., which are necessary for the production and sort out the remaining things from the Maintenance Location.
Straighten
Organize the Maintenance Location in such a way that the work force can be utilized effectively.
Shine
Keep the Maintenance / Work Location neat and clean to have better visibility.
Standards
Define the standards to make the above three activities effective.
Sustain
Ensure that the standards are applied regularly to keep the process running flawlessly in the Long term.
Pillars of Total Productive Maintenance:
Maintenance work orders play a vital role in effective maintenance management within an organization, impacting various facets of asset and facility maintenance. Key reasons for their significance include:
- Autonomous Maintenance: Enables the Resource who manages the asset to carry out the routine maintenance activities instead of providing it to the maintenance team. By this way, Maintenance team can focus on higher priority jobs and the resource who manages the asset will be proactive and identify the Potential failures.
- Planned Maintenance: Scheduled Maintenance followed by the Maintenance team of organization to maintain the assets periodically as per the OEM Recommendation / Industry Standards.
- Quality Maintenance: Focusses on the design flaws and the Quality issues in the Product. Promotes repetitive root cause analysis and incorporate the preventive measures to improve the quality.
- Early Equipment Management: Applies the learnings based on the equipment maintenance and enhanced maintenances schedules in the New equipment which would eventually makes the equipment to attain the expected performance level soon.
- Continuous / Focussed Improvement: Promotes collaboration among teams for incremental process improvements and problem solving through cross-functional approaches, with the common intention of creating an organizational culture of focused, continuous improvement.
- Training and Skill Development: Provides continuously improves and training for the Workers to upskill their knowledge which in turn has the positive impact in the Production.
- Health Safety and Environment: Promoter healthier and safe work environment. Planned maintenance activities eliminate the risk of mishaps, ensuring accident-free workplace environments.
- TPM in Administration: Like maintenance and operations departments, Administration teams working behind the scenes can contribute to the improvement in production by minimizing the loses.
Goals of TPM
- No Stops: Refers to the downtime of the assets which ends up in the productivity loss. TPM aims to achieve NO STOPS to enhance the productivity.
- No Stops / Slow Running: Aims to eliminate the performance issues of the assets / small stoppage such as planned downtime to improve the productivity.
- No Defects: Promotes the high level standards in the quality by achieving the “Zero Defects” state.
- OEE (Overall Equipment Effectiveness): Focusses on over all equipment effectiveness and aims to achieve a state called “Perfect Production” by eliminating the defects and wastages.
Conclusion
A well-structured preventive maintenance inspection program is integral for optimizing asset performance, reducing downtime, and achieving long-term cost savings. Leveraging technology and data-driven approaches further enhances the effectiveness of preventive maintenance practices, providing organizations with a proactive means to manage and maintain their assets efficiently.
Author:
Jawahar
Jothilingam
Product Specialist - EAM360
