Total Productive Maintenance (TPM) is a management philosophy that places the focus on the maintenance of equipment as the responsibility of ALL employees. This is in contrast to the traditional view that maintenance work should be performed by a tradesperson who will return a machine to a working state when it is broken. The philosophy of TPM is that the maintenance function is shared by many to continually improve the machine's performance, and continually increase the value-add time provided by the machine.

What to implement for a successful TPM program:

* Implement autonomous maintenance. That is, involve the employees that operate the equipment to maintain the equipment to the degree that they are qualified. As the TPM program develops, train the employees to do more. A good start for this is simply inspection by means of cleaning. Warning: safety training, and proper cleaning technique training is required. A lot of quick damage can be caused by cleaning with the incorrect cleaning agent, or allowing the cleaning agent to penetrate into the machine where it should not.

* Implement a planned maintenance schedule. Incorporate the maintenance schedule directly into the production schedule. It may seem like lost time initially, especially to the production manager, but in the long run, it will result in more production time available. Include the maintenance time on the production schedule as soon as the scheduling window opens up, even if it is months in advance.

* Use a Computerized Maintenance Management System (CMMS). There are hundreds of CMMS's available, and typically include many more functions than required. The function to generate work orders is the most important. It will ensure by means of work orders remaining 'open', that any incomplete maintenance activity stays "on the radar screen". The work orders can also provide the autonomous program with clear instructions, a checklist of the work to be completed, a means to record observations, and an opportunity to add a sign-off.

* Implement a team approach. Create small teams consisting of the machine operators, set-up personnel, maintenance personnel, supervision, etc. Allow the teams to meet on a regular basis to review reasons for unscheduled downtime and develop solutions. Ensure that notes and action plans from the meetings are visible in the workplace.

* Implement a 5S program. 5S is a Japanese philosophy to maintain an organized and clean workplace. Take the 5S program beyond the machine work centres, and implement the program for the maintenance shop, spare parts storage and maintenance office.

 

Lenko & Associates

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TPM