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Total Productive Maintenance
Total Productive Maintenance (TPM) is an initiative for optimizing the effectiveness of manufacturing equipment. TPM is team-based productive maintenance and involves every level and function in the organization, from top executives to the shop floor. The goal of TPM is "profitable PM." This requires you to not only prevent breakdowns and defects, but to do so in ways that are efficient and economical.
To achieve this goal you will need to master four techniques Preventive maintenance - preventing breakdowns
Corrective maintenance - improving or modifying equipment to prevent breakdowns or to make
maintenance easier
Maintenance prevention -designing and installing equipment that needs little or no maintenance
Breakdown maintenance - repairing after breakdowns occur
FACTS AND CONCEPTS
TPM addresses the entire production system life cycle and builds a concrete, shop floor-based
system to prevent all losses. Its aims include the elimination of all accidents, defects,
and breakdowns.
Everyone participates in TPM, from top executives to shop floor employees
TPM achieves zero losses through overlapping team activities
A TPM development program consists of activities aimed specifically at eradicating the six big
losses that sap efficiency and drain productivity:
Breakdowns
Setup and adjustment loss
Idling and minor stoppages
Reduced speed
Defects and rework
Startup yield loss
Team activities are basic to TPM. TPM activities are carried out by teams at top management,
middle management, and shop floor levels. Each type of team has its own objectives
and part to play.
Safety is a cornerstone of TPM. The basic principle behind TPM safety activities is to address
dangerous conditions and behavior before they cause accidents.
Workplace organization and discipline, regular inspections and servicing, and standardization
of work procedures are the three basic principles of safety. All are essential elements in creating
a safe workplace.
Sustaining smooth production means avoiding equipment breakdowns and defects. You will need
to install suitable equipment in the first place and keep it functioning properly through three
types of activities:
Daily maintenance (cleaning, checking, lubricating, and tightening) to prevent deterioration
Periodic inspections or equipment diagnosis to measure deterioration
Restoration to correct and recover from deterioration
Achieving the goals of TPM requires activities in eight key areas:
Focused improvement (kaizen) to make equipment more efficient
Autonomous maintenance activities
Planned maintenance for the maintenance department
Technical training in equipment maintenance and operation
An early equipment management program
Quality maintenance activities
A system for increasing the efficiency of administrative and support functions
A system for management of safety and environmental issues
The following 8 activities are the most common for implementing TPM effectively. They form the foundation to support any TPM effort. Not all of these strategies are implemented at once...you will develop a sequence that fits your situation.
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