Total productive maintenance (TPM), Goals, Pillars of TPM, TPM Implementation Steps, TPM kick-off

Total productive maintenance (TPM)

Approach where workers perform preventive maintenance on the machine they operate

• Employees are given greater responsibility for quality, productivity, & the general functioning of the system
• Maintenance management which recognizes the importance of reliability, maintenance & economic efficiency in plant design

Goals

• Improve equipment effectiveness
• Achieve autonomous maintenance
• Plan maintenance
• Train all staff in relevant maintenance skills
• Achieve early equipment management by ‘maintenance prevention’ (MP)
• Encouraging input from all employees
• Using teams for continuous improvement

Principles of Prevention

• Maintenance of normal conditions
• Early discovery of abnormalities
• Prompt response

Eight pillars

TPM Implementation (Steps)

Announce top management’s decision to introduce TPM

• State TPM objectives in a company newsletter
• Place articles on TPM in the company newspaper

Introductory education campaign

• Seminars for managers
• Slide presentations for all employees

TPM Promotion

• Special committees at every level to promote TPM
• Newsletters, Articles, Videos, Posters

Establish basic TPM policies and goals

• Analyze existing conditions
• Set goals, Predict results

Preparation and Formulation of a master plan

• A master plan lays out your goals, what you will do to achieve them and when you will achieve them
• Detailed plans for each pillar have to be prepared

TPM kick-off

• The main kick-off to TPM should take the form of a formal presentation with all the employees attending
• This opportunity can be used to gain the full support of the employees
• Invite external customers, affiliated and subcontracting companies

Develop an equipment management program

• The tools of Total Quality Management and Continuous Improvement are applied to the management and improvement of equipment
• Form project teams
• Select model equipment, identify equipment problems, analyze equipment problems, develop solutions and proposals for improvement
• Typical membership of a team, five to seven operators, a maintenance person, a technical expert
• Tools Pareto, Cause & effect, Root cause, Methods Analysis

Develop a planned maintenance program

• Set up plans and schedules to carry out work on equipment before it breaks down, in order to extend the life of the equipment
• Include periodic and predictive maintenance
•  Include management of spare parts and tools

Develop an autonomous maintenance program

• A handing-over of maintenance tasks from specialized maintenance personnel to production operators
• Promote the seven steps
• Tasks to hand over, cleaning, lubricating, inspecting, set-up and adjustment

Increase skills of production and maintenance personnel

• The training sessions must be planned shortly after the kick-off presentation.
• 2 major components, soft skills training, technical training
• Have leaders share information with group members

Develop early equipment management program

• The principle of designing for maintenance prevention can be applied to new products, and to new and existing machines.
• New products must be designed so that they can be easily produced on new or existing machines
• New machines must be designed for easier operations, changeover and maintenance
• Existing machines: analyze historical records for trends of types of failures, frequency of component failures, root causes of failures
• Determine how to eliminate the problem and reduce maintenance through an equipment design change or by changing the process

Perfect TPM implementation and raise TPM levels

• Evaluate for the PM Award: The Japanese Institute for Productive Maintenance runs the annual PM Excellence Award
• Set higher goals