What is Autonomous Maintenance? This is understandable as AM is one of the key distinguishing features of TPM and also one of the most important activities when understood correctly. To understand AM correctly it needs to be seen as an improvement activity within TPM, rather than production teams taking on maintenance activities.
TPM Total Productive Maintenance is a holistic approach to equipment maintenance that strives to achieve perfect production: No Accidents TPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.
The implementation of a TPM program creates a shared responsibility for equipment that encourages greater involvement by plant floor workers. In the right environment this can be very effective in improving productivity increasing up time, reducing cycle times, and eliminating defects.
Traditional TPM The traditional approach to TPM was developed in the s and consists of 5S as a foundation and eight supporting activities sometimes referred to as pillars. The 5S Foundation The goal of 5S is to create a work environment that is clean and well-organized.
It consists of five elements: Sort eliminate anything that is not truly needed in the work area Set in Order organize the remaining items Shine clean and inspect the work area Standardize create standards for performing the above three activities Sustain ensure the standards are regularly applied It should be reasonably intuitive how 5S creates a foundation for well-running equipment.
For example, in a clean and well-organized work environment, tools and parts are much easier to find, and it is much easier to spot emerging issues such as fluid leaks, material spills, metal shavings from unexpected wear, hairline cracks in mechanisms, etc.
The Eight Pillars The eight pillars of TPM are mostly focused on proactive and preventative techniques for improving equipment reliability. Pillar How Does It Help? Autonomous Maintenance Places responsibility for routine maintenance, such as cleaning, lubricating, and inspection, in the hands of operators.
Ensures equipment is well-cleaned and lubricated. Identifies emergent issues before they become failures. Frees maintenance personnel for higher-level tasks.
Significantly reduces instances of unplanned stop time. Enables most maintenance to be planned for times when equipment is not scheduled for production. Reduces inventory through better control of wear-prone and failure-prone parts. Quality Maintenance Design error detection and prevention into production processes.
Apply Root Cause Analysis to eliminate recurring sources of quality defects. Specifically targets quality issues with improvement projects focused on removing root sources of defects. Reduces number of defects. Reduces cost by catching defects early it is expensive and unreliable to find defects through inspection.
Focused Improvement Have small groups of employees work together proactively to achieve regular, incremental improvements in equipment operation.
Recurring problems are identified and resolved by cross-functional teams. Combines the collective talents of a company to create an engine for continuous improvement.
Early Equipment Management Directs practical knowledge and understanding of manufacturing equipment gained through TPM towards improving the design of new equipment. New equipment reaches planned performance levels much faster due to fewer startup issues.
Maintenance is simpler and more robust due to practical review and employee involvement prior to installation. Applies to operators, maintenance personnel and managers. Operators develop skills to routinely maintain equipment and identify emerging problems.
Maintenance personnel learn techniques for proactive and preventative maintenance. Managers are trained on TPM principles as well as on employee coaching and development. Safety, Health, Environment Maintain a safe and healthy working environment. Eliminates potential health and safety risks, resulting in a safer workplace.
Specifically targets the goal of an accident-free workplace. Extends TPM benefits beyond the plant floor by addressing waste in administrative functions. Supports production through improved administrative operations e. OEE consists of three underlying components, each of which maps to one of the TPM goals set out at the beginning of this topic, and each of which takes into account a different type of productivity loss.Total Productive Maintenance (TPM) SMJ Project Management & Maintenance Engrg.
Semester I / Introduction to TPM What is TPM? Total Productive Maintenance (TPM) is both a philosophy to permeate throughout an operating company touching people of all levels a collection of techniques and practices aimed at maximizing the effectiveness (best possible return) of business .
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TQMI offers the most valued Total Productive Maintenance (TPM) training in India that aims at maintaining and improving the integrity of production and quality systems that . Total productive maintenance (TPM) is a strategy that operates according to the idea that everyone in a facility should participate in maintenance, rather than just the maintenance team.
This approach uses the skills of all employees and seeks to incorporate maintenance into the everyday performance of a facility.
What is TPM – Total Productive Maintenance 09/20/ Making assets work to add value. To keep value flowing, and maximize your sales and margin contribution, you must engage everyone in establishing and maintaining equipment and process reliability.