Total Productive Maintenance | TPM
Total Productive Maintenance ( TPM) is a systematic approach to understanding the equipment’s function, the equipment’s relationship to product quality and the likely cause and frequency of failure of the critical equipment components. It prevents quality defects and breakdowns, eliminates the need for equipment adjustments, and makes the work easier and safer for equipment operators.
Total Productive Maintenance ( TPM) aimed at maximizing equipment effectiveness through the optimization of equipment availability , performances , efficiency and product quality.
Benefits of Total Productive Maintenance ( TPM)
Productivity Improvement – Productivity is improved through fewer losses in the company
Quality Improvement – Quality is improved as a result , that the failures and malfunctions is reduced
Cost Reduction – THE cost is reduced because the losses and other not value added work is reduced
Employee Ownership – Ownership of equipment by operators through Autonomous Maintenance
Employee Confidence – “Zero failure”, “zero defect” and “zero accident” conditions builds employee self-confidence
Improved working environment – Clean working conditions provides a good working environment
Increased Plant Reliability
Customer Satisfaction – TPM leads to high delivery performance and customer satisfaction
Six Big Losses of Total Productive Maintenance (TPM)
- Breakdown losses
- Setup and adjustment losses
- Idling and minor stoppage losses
- Speed losses
- Quality defects and rework losses
- Strat-up/ yield losses
Overall Equipment Effectiveness (OEE)
The six big losses are combined into one measure of overall equipment effectiveness
(OEE) :
OEE = Equipment availability x Performance Efficiency x Rate of Quality Products
How To Improve Overall Equipment Effectiveness (OEE) ?
Improve the 3 components of OEE by:
- Equipment availability: Improved by eliminating breakdowns, setup/ adjustment losses, and other stoppage losses
- Performance Efficiency: Improved by eliminating speed losses, minor stoppages, and idling
- Rate of Quality Products: Improved by eliminating quality defects in process and during start-up
Eight Pillars of Total Productive Maintenance ( TPM)
- Focus Improvement
- Autonomous Maintenance
- Planned Maintenance
- Training
- Early Equipment Management (EEM)
- Quality Maintenance
- Efficient Administration
- Safety & Environment
Nine Essentials of Total Productive Maintenance ( TPM)
- Self maintained work place
- Elimination of the 6 big losses
- Zero breakdowns
- Zero defects
- Optimal life and availability of tools
- Self-improvement
- Short production-development time and low machine life cost
- Productivity in indirect departments
- Zero Accidents
Related pages that you may be interested in:
- Lean
- Lean Implementation Tips
- Value Stream Mapping | VSM
- 5S
- Lean Office
- Single Minute Exchange of Die | SMED
- Kaizen Event
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