Total Productive Maintenance (TPM) is an approach to equipment improvement used to reduce operating & maintenance costs, improve quality and deliver improved reliability. Originally developed among Toyota's supply base, TPM has become an essential Lean based approach enabling companies from all industry sectors to achieve World Class Maintenance Processes an essential part of any Operational Excellence journey. Focusing improvement activities on production plant & equipment and being used to integrate maintenance with production.
The ultimate goals of TPM are zero accidents, zero breakdowns and zero defects – safety, performance & quality. This is coupled with the objective of involving everyone in equipment improvement and breaking down barriers between departments. The point of TPM is to measure Overall Equipment Effectiveness (OEE) and perform Loss Analysis to give both a baseline for continuous improvement and to identify improvement priorities.
TPM consists of 8 pillars of activities that impact all areas of the organisation, this is built on a solid foundation of the lean 5s concept, meaning a clean, visually organised workplace/equipment area that is self-maintaining. Briefly explained below;
5S concept is considered the foundation of the lean TPM programme because without it the initiative will struggle under the weight of disorganisation, indiscipline and inefficiency. It is important because it results in a clean, visually organised workplace/equipment area that is self-maintaining.
The 5S programme sets the pace for the introduction of Total Productive Maintenance and must be fully mature before any attempts are made to implement other aspects of the system
Autonomous Maintenance places the responsibility of basic maintenance activities in the hands of the operators. CLAIR - Clean, Lubricate, Adjust, Inspect and Repair activities are front-line operation maintenance activities used to keep equipment in proper working order and minimise the need for extensive corrective work activities through early defect detection - Ensures equipment ownership from operators.
Planned maintenance is the scheduling of maintenance activities based on observed behaviour of machines such as failure rates and breakdowns, PMO, Preventive Maintenance Optimisation is commonly carried out here to identify what maintenance should be carried out to mitigate against unexpected failures.
Quality Maintenance addresses the issue of quality by ensuring equipment is able to detect and prevent errors during production. By detecting errors, processes become reliable enough to produce the right specification first time, error detection and prevention is designed into the production processes.
Focused Improvement - Kaizen, where cross-functional teams are assembled with the main working on problematic equipment and coming up with and implementing equipment improvements, advantageous as quick gains are made which helps in promoting the lean methodology to workers who may not have bought in to the programme.
Design & Early Equipment Management, uses the experience gathered from previous maintenance improvement activities to ensure that new machinery reaches its optimal performance much early than usual. Using the input from the people who use these machines on a daily basis, suppliers of the equipment can improve the maintainability and operability in the next iteration of their products. Such an approach has a positive impact on profitability of the company as maintenance costs are dramatically reduced.
Education & Training, is concerned with filling the knowledge gap that exists in an organisation when it comes to total productive maintenance. The goal is to have a multi-skilled workforce and create a pool of in-house experts to be able to support all aspects of TPM. Under this pillar we should assess technical training needs and be able to assess current status of skill sets – a training plan based on gap analysis would then be established.
TPM in the Office, taking TPM to the administrative functions is the next logical step in the total productive maintenance programme so as to have the whole organisation speaking from the same page. As these are supportive functions, making them understand and apply the principles of lean in their own operations makes it easy for them to provide efficient service to the main value-creating processes. The TPM principles can also be applied as stand-alone techniques to improve the efficiency of these supportive functions
HSSE Management, ensures that all workers are provided with an environment that is safe and that all conditions that are harmful to their well-being are eliminated or reduced to a level of as low as reasonably practical (ALARP) – the ultimate goal of “Zero Accidents”. The cross-functional teams will work towards making machines safe to use by the operators by putting in place such features as guards, works standards, use of personal protective equipment and first-aid kits in the work-area. HSE requirements and improvements should be at the forefront of any Equipment Improvement event. 5s and equipment improvement activities will undoubtedly have a positive effect on all personnel working in the facility.
i4 business improvements ultimate aim is, “to help businesses to help themselves”, by working hand in hand with the client to firstly understand and define the exact maintenance & reliability needs for their operation.
We can provide varying levels of expert support in the field of TPM from full operational implemention to specific Equipment Improvement Activity (EIA) events for your most problematic equipment.
In addition we have a variety of assessments & tools that can be used to examine your current maintenance & reliability practices within your operation, this will help you identify key areas of opportunity.
i4 business improvements ultimate aim is, “to help businesses to help themselves”, by working hand in hand with the client to firstly fully understand and define the exact maintenance & reliability needs for their operation.
We can provide varying levels of expert support in the field of TPM from full operational implementions to specific Equipment Improvement Activity (EIA) events for your most problematic equipment using our unique structured process approach.
The aim of an Equipment improvement Activity - EIA is to improve the condition of unreliable equipment by returning it to an ‘as new’ or optimised condition as possible, that enables the operator to maintain the equipment through Autonomous Maintenance activities (Cleaning, Lubricating, Adjusting, Inspecting and conducting minor Repairs).
The benefit of these proactive activities is the early detection and correction of defects that lead to unplanned equipment downtime and escalation in reactive maintenance costs, and with key Operator / Maintenance involvement in the process, ownership and pride in the equipment is restored.
The objective of the Equipment Improvement Activity process is to implement a standard process across the organisation that enables and promotes effective EIA’s in order to achieve the culture of Autonomous Maintenance an essential element of TPM - Total Productive Maintenance.
Where do we start?
Achieving the ultimate goal of zero defects, zero breakdowns and an effective workplace design may seem a little daunting to an organisation starting out on a TPM journey.
Most organisations generally start by targeting unreliable equipment so called "bad actors", then systematically target them one by one based on priority. The main benefit of this approach is the immediate buy in, once personnel and the business see the value and what is possible with this approach on one small piece of equipment, then it will difficult not to keep it going and move on to the next.
Another factor to consider would be the existing lean maturity of your operation/organisation, TPM may be the next step on the lean journey with the basic lean principles of 5s, visual management and kazien already embedded in areas of the business or it may be the intended starting point for your lean journey.
As always our approach would be defined and tailored to suit your specific needs.
Provide facilitation support for specific stand alone equipment improvement projects based on your immediate need
Support the implementation of the TPM methodology in to your operation
Develop your own people to be able to lead & support Equipment Improvement Activities moving forward
Please get in touch, to see how this approach could benefit your operation...