Total productive maintenance (TPM) plays a very important role in any lean manufacturing execution and it is not possible to improve the process unless we rely on the performance of the machines. Total Productive Maintenance was developed in a company called Nippondenso (supplier of Toyota).
In any manufacturing plant, productivity of the equipment is given utmost importance with very little investment. Through total productive maintenance optimal productivity can be obtained.
Total Productive Maintenance is a unique approach for maintaining the equipment to get perfect production. It also includes a safe working environment.
Total productive maintenance plays a very important role in maximizing the operational efficiency of the equipment. It also plays a very strong role in empowering operators to help maintain their equipment.
The main objective of Total Productive Maintenance is to improve a manufacturing plant and its productivity but with only a fair investment.
The oldest method of TPM was developed in 1960s and consists of 5S. 5S is foundation and consists of eight pillars.
5S was developed in Japan and was found one of the technique that enabled Just in Time Manufacturing.
The aim of 5S foundation is to create a work environment which is clean and well- structured and organized. There are 5 elements in this.
· Sort (Seiri) – Remove anything that is not truly not needed in workplace.
· Set in Order (Seiton) – Arranging the remaining items so that they can be selected easily for use.
· Shine (Seiso) – Cleaning as well as inspecting the work place.
· Standardize (Seiketsu) – Creating some standards for doing all the three activities.
· Sustain (Shitsuke) – Ensuring that the standards are applied regularly and performing regular audits.
It ought to be sensibly natural how 5S creates a foundation for well running machinery. For example, in a clean and well-organized work environment tools are easier to find, and it is much easier to spot various defects such as any leaks, various cracks in any machines, etc.
The eight pillars of Total Productive Maintenance are mainly focussed on preventive maintenance.
· Autonomous Maintenance
· Planned Maintenance
· Focused Improvement
· Training and Education
· Early Equipment Management
· Quality Maintenance
· Safety, Health and Environment
· Total Productive Maintenance in Administration
The basic maintenance responsibility of the machinery relies in the hands of operator.
Timely scheduled maintenance based on equipment previous failure rate
Focus on improving the reliability as well as performance of equipment.
Training and Education
Providing training to the operators to bridge the knowledge and skill gap
Early Equipment Management
Reduce the amount of maintenance required by the equipment
Improving quality of the equipment to further minimize the defects
Safety, Health and Environment
Taking precautionary measures to prevent accidents by improving safety and maintaining a healthy work environment
Total Productive Maintenance in Administration
Spreading the TPM principles to administration functions
Total productive Maintenance is a long and well-planned process that should be worked out with full participation from all the workers across the functions and levels of organization.
Evaluate Current TPM Level
Basic TPM Education
Formation of TPM Committee
Developing of TPM Implementation Plan
training for Employees