What is Total Productive Maintenance (TPM)?
Benefits of total productive maintenance
Total productive maintenance has three main advantages, which are outlined below:
1. Creating a safer workplace
The total productive maintenance approach educates team members on how to identify, maintain, and keep track of the caliber of the equipment they use. This results in a higher rate of spotting potential flaws in a tool or facility because every piece of equipment in use is constantly being monitored organically. Additionally, because damaged equipment is repaired more quickly as a result, workplaces are safer because the equipment is always in good condition. Team members who have received training in identifying hazards can avoid potentially hazardous areas and let others know about them to stay safe.
2. Having fewer breakdowns
In addition to making the workplace safer, constant monitoring of heavily used equipment enables team members to frequently anticipate and avoid potential problems before they arise. This entails instructing team members on how to repair equipment and where to find any necessary parts at the organizational level. Additionally, this can help a business order replacement parts for equipment that frequently breaks down, minimizing equipment downtime. The same is true for facilities; maintaining them in top shape can result in cleaner workspaces and happier teams.
3. Generating better overall performance
The overall production of a facility increases as team members are happier, production equipment experiences fewer failures, and there is less downtime. This can be beneficial when thinking about the price of training new team members and creating strategies and procedures to deal with any difficulties that equipment or facilities may present. Due to the fact that an organization won’t need to hire specialists to repair equipment on a constant basis, this maintenance strategy could also increase profits. For instance, skilled kitchen staff can maintain their knives, ovens, and stoves without needing to hire skilled mechanics and knife sharpeners, saving money on services.
What is total productive maintenance?
An approach to facility and equipment maintenance known as “total productive maintenance” is focused on developing the ideal means of production. A facility and piece of machinery that never experiences downtime, is always operating at maximum efficiency, and is defect-free is the ideal means of production. Businesses that practice this type of upkeep give their employees safer working environments. A specific kind of organization known as total productive maintenance encourages its team members to maintain their own facilities and equipment without making a distinction between production and maintenance team members.
Pillars of total productive maintenance
An organization can use this method of maintenance by implementing the following eight productive maintenance pillars:
1. Autonomous maintenance
This is the pillar that assigns users of facilities, machinery, and other items with overall responsibility for their upkeep. This can give team members a sense of greater control over the working environment and the functionality of their equipment. There are several benefits to this pillar, including:
2. Planned maintenance
This is the foundational element of total productive maintenance that enables a company to develop a planned schedule for facility and equipment maintenance. The company can base the schedule on a variety of things, such as expected equipment failure dates or measured failure rates. Benefits of this pillar include:
3. Quality integration
This pillar concentrates on creating standards, best practices, and procedures for error detection to get rid of reoccurring mistakes in the facility, equipment, and machinery. This may entail using root cause analysis to trace problems back to their original sources. Benefits of this pillar include:
4. Focused improvement
This is the foundational element that enables teams to collaborate and produce proactive plans to keep machinery in good working order and suggest small but significant adjustments for managing and maintaining machinery and facilities. This may also entail creating response strategies for common workplace challenges using fictitious scenarios for teams and individuals. Benefits of this pillar include:
5. Early equipment management
This is the pillar that guides the organizational knowledge that team members and an organization acquire through working with manufacturing equipment and performing total productive maintenance to new equipment. This can help a company decide whether it needs new equipment for its operations and what those items’ costs and advantages are. The benefits of this pillar include:
6. Training and education
The organization’s members, including operators, maintenance workers, and managers, are the focus of this pillar. It entails ensuring that each employee of an organization has received training on how to maintain equipment and achieve total productive maintenance objectives. The benefits of this pillar include:
7. Safety, health and the environment
This pillar is concerned with maintaining a secure workplace. It entails having knowledge of the risks and production processes in a facility. The benefits of this pillar include:
8. Total productive maintenance in administration
This pillar incorporates administrative tasks into the objectives and methods of total productive maintenance. It entails using the principles to create unified goals, projects, and growth at all organizational levels. The benefits of this pillar include:
How to implement total productive maintenance
You can use the following five steps to put a total productive maintenance approach into practice:
1. Identify an initial area of improvement
Finding a place for improvement is the first step in the implementation process. There are several approaches you can take to this step:
2. Restore equipment to best operating condition
Next, eliminate any unnecessary equipment in the workplace. You can do so by completing the following actions:
3. Start measuring overall equipment effectiveness
It’s crucial to evaluate the efficiency of your machinery because doing so can help you understand the total output a system of machinery produces. This can assist you in identifying new target areas, developing procedures and standards for each, and implementing total productive maintenance in a comprehensive manner. This step can assist you in identifying problems and learning about existing procedures that don’t require improvement.
4. Address the major challenge
Deal with the machinery and procedures that cause the company the most problems or the greatest losses. This is advantageous because it can increase output quickly and offer fresh perspectives on the effectiveness of your equipment as a whole as you alter some processes. This step allows you to identify the underlying causes of problems and take swift action to solve them before they result in system failure.
5. Introduce proactive maintenance techniques
Lastly, incorporate total productive maintenance techniques into actions that teams and individuals can carry out. There are a few parts to this process:
What is Total Productive Maintenance explain with an example?
Total productive maintenance (TPM) is a strategy that promotes participation in maintenance by everyone in a facility, not just the maintenance team. This strategy makes use of the talents of all personnel and aims to integrate maintenance into a facility’s regular operations.
What is the purpose of Total Productive Maintenance?
Examples of Total Productive Maintenance Machine operators regularly clean, grease, lubricate, inspect, and replace parts. They also identify and document inspection points. Workers at the plant tidy up their workspace, removing waste materials like debris and unused tools.