Implementation
TPM has basically 3 goals - Zero Product Defects, Zero Equipment Unplanned Failures and Zero Accidents. It sets out to achieve these goals by Gap Analysis of previous historical records of Product Defects, Equipment Failures and Accidents. Then through a clear understanding of this Gap Analysis (Fishbone Cause-Effect Analysis, Why-Why Cause-Effect Analysis, and P-M Analysis) plan a physical investigation to discover new latent fuguai (slight deterioration) during the first step in TPM Autonomous Maintenance called "Initial Cleaning".
Many companies struggle to implement TPM due to 2 main reasons. First is having insufficient knowledge and skills especially in understanding the linkages between the 8 Pillar-Activities in TPM. It does not help in that most TPM books are long on the theories but scanty on the implementation details. The second reason is that TPM requires more time, resources and efforts than most of these companies believe they can afford. A typical TPM implementation requires company-wide participation and full results can only be seen after 3 years and sometimes 5 years. The main reason for this long duration is due to the basic involvement and training required for Autonomous Maintenance participation where operators participate in the restoring the equipment to its original capability and condition and then improving the equipment.
An effective Fast-Track TPM Implementation Approach has been successful in a Paper Mill and Electronics Industries and documented. It circumvented this problem by assigning Project Teams to do Autonomous Maintenance for the AM Steps of 1) Initial Cleaning and 2) Eliminating Sources of Contamination and Improving Equipment Accessibility. Production Operators take over the Autonomous Maintenance after the AM Step 3 (Initial Maintenance Standards) has been established. This has been proven to reduce TPM implementation time by about 50%.
TPM identifies the 7 losses (types of waste) (muda), namely set-up and initial adjustment time, equipment breakdown time, idling and minor losses, speed (cycle time) losses, start-up quality losses, and in process quality losses, and then works systematically to eliminate them by making improvements (kaizen). TPM has 8 pillars of activity, each being set to achieve a “zero” target. These 8 pillars are the following: focussed improvement (Kobetsu Kaizen); autonomous maintenance (Jishu Hozen); planned maintenance; training and education; early-phase management; quality maintenance (Hinshitsu Hozen); office TPM; and safety, health, and environment. Few organisation also add Pillars according to their Work Place like: Tools Management; Information Technology & more. The Base for the TPM Activity is 5S; Seiri (Sorting out the required or not required items); Seition (Systematic Arrangement of the required items); Seiso (Cleaniness); Seiketsu (Standardisation); Shitsuke (Self Discipline).
The Pillars & their details
a) Efficient Equipment Utilisation
b) Efficient Worker Utilisation
c) Efficient Material & Energy Utilisation
- Focused improvement (Kobetsu Kaizen) - Continuously even small steps of improvement.
- Planned Maintenance - It focusses on Increasing Availability of Equipments & reducing Breakdown of Machines.
- Initial Control - To establish the system to launch the production of new product & new equipment in a minimum run up time.
- Education & Training - Formation of Autonomous workers who have skill & technique for autonomous maintenance.
- Autonomous Maintenance (Jishu Hozen) - It means "Maintaining one's equipment by oneself". There are 7 Steps in & Activities of Jishu Hozen.
- Quality Maintenance (Hinshitsu Hozen) - Quality Maintenance is establishment of machine conditions that will not allow the occurrence of defects & control of such conditions is required to sustain Zero Defect.
- Office TPM - To make an efficient working office that eliminate losses.
- Safety, Hygiene & Environment - The main role of SHE (Safety, Hygiene & Environment) is to create Safe & healthy work place where accidents do not occur, uncover & improve hazardous areas & do activities that preserve environment.
Other Pillars Like: Tools Management - To increase the availability of Equipment by reducing Tool Resetting Time, To reduce Tool Consumption Cost & to increase the tool life.
TPM success measurement - A set of performance metrics which is considered to fit well in a lean manufacturing/TPM environment is overall equipment effectiveness, or OEE. For advanced TPM world class practitioners, the OEE cannot be converted to costs using Target Costing Management (TCM) OEE measurements are used as a guide to the potential improvement that can be made to an equipment. and by identifying which of the 6 losses is the greater, then the techniques applicable to that type of loss. Consistent application of the applicable improvement techniques to the sources of major losses will positively impact the performance of that equipment.
Using a criticality analysis across the factory should identify which equipments should be improved first, also to gain the quickest overall factory performance.
The use of Cost Deployment is quite rare, but can be very useful in identifying the priority for selective TPM deployment.
Steps to start TPM are Identifying the key people
- Management should learn the philosophy.
- Management must promote the philosophy.
- Training for all the employees.
- Identify the areas where improvement are needed.
- Make an implementation plan.
- Form an autonomous group.
Read more about this topic: Total Productive Maintenance