What is TPM?
Total Productive Maintenance is a team based approach to ensuring that production equipment is functioning in a perfect order. The goals of TPM are ZERO downtime, ZERO defects and ZERO accidents. A key elements of TPM is Autonomous Maintenance which incorporates basic maintenance duties into operator's work schedule. This enables specialists from the Maintenance Department to switch from fixing breakdowns mode to Preventive, Predictive and other specialized Maintenance tasks.
TPM Progress is measured by OEE (Overall Equipment Effectiveness) which ties together machine availability, performance and quality. World Class companies can achieve OEE on the level of 85%
Autonomous Maintenance Workshop
combining roles of operators and maintenance specialists into a shared responsibility for maintaining equipment. The transition to full workplace ownership by operators is divided into seven steps, each followed by a management audit. Topics covered during the workshop include overview of TPM, 6 Big Losses, Preventive Maintenance and a seven step Autonomous Maintenance implementation.
The practical part of the workshop focuses on the first three steps of AM: Initial Cleaning, Elimination of the Sources of Contamination and Cleaning and Lubrication Standards. A pilot machine is used as a training ground to learn machine functions, clean mechanisms and identify problem areas, design cleaning, lubrication and inspection standards. Participants also learn how to calculate OEE, a key metric in TPM implementation. At the end of the workshop they conduct a self-audit and develop an action plan for future improvements.
Course in TPM Foundations
The class is an overview of the foundations of Total Productive Maintenance. A wholesome approach to equipment management is compared to traditional maintenance practices. Participants learn Focused Improvement techniques that eliminate 6 Big Losses decreasing machine efficiency. The course describes in detail TPM measures: OEE, MTBF and MTTR. A 7 Step Autonomous Maintenance program formally involving operators in the maintenance activities is covered in great detail. Participants also learn elements of Planned Maintenance that organizes the work of Maintenance Department: Corrective, Preventive and Predictive Maintenance as well as Early Equipment Management and Quality Maintenance. The course is illustrated with case studies from Polish and foreign companies that use TPM. Finally, a 12 step TPM implementation program in a company is described together with the requirements for a successful implementation
12 steps to TPM implementation
TPM is a company wide approach that must involve all employees, from the CEO down to machine operators. To ensure this success, most implementation programs include the following 12 steps:
1. Analyze current conditions
2. Train management
3. Form program
4. Plan implementation
5. Announce decision to launch
6. Train workforce
7. Hold kick off ceremony
8. Form shopfloor teams and eliminate Six Big Losses
9. Implement Autonomous Maintenance
10. Implement Preventive Maintenance
11. Implement Predictive and Maintenance Prevention Programs
12. Ensure Continuous Improvement
Definition of 6 Big Losses
1. Breakdown losses - a loss of machine function that requires a repair
2. Setup and adjustment losses - changing of product or production parameters
3. Micro stoppages and idling losses- short stoppages not caused by a breakdown, jamming, idle running, etc.
4. Speed losses - lowering machine operational speed
5. Quality and repair losses - manufacturing products not conforming to customer requirement
6. Production start up losses - time and material lost when starting production