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Productivity improvement through Total Productive Maintenance (TPM): Part I of III

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More and more companies are using TPM® as a means of keeping key machines up & running. The objective of TPM® is to eliminate the equipment downtime. It focuses on overall equipment effectiveness (OEE), covering areas like breakdowns, setup time, capacity, etc.

Productivity Improvement

The OEE calculations rolls the “6 big losses” of TPM® into one number that represents the effective operating rate for any equipment.

6 losses

Total Productive Maintenance is also defined as:

TOTAL: Business Wide
PRODUCTIVE: Improve equipment performance
MAINTENANCE: Machine support system

To become world class

  • We need world class processes
  • World-class people
  • World-class machines

TPM® is a tool which ensures that we attain & sustain world-class machines

If machines are poorly maintained…..Break downs will occur – which is Muda, Production loss will happen, Product quality will be unstable, Safety stocks will be built as we are not sure when the M/c will stop again! Spare part consumption will be more, etc

TPM® was started by JIPM & the TPM® Targets are Zero (unplanned) stoppages, Zero quality defects (due to m/c), Zero accidents, Over 85% OEE. TPM®…is a culture that focuses on improving the effectiveness of the plant, equipment and processes through the empowerment of PEOPLE.

TPM® is:

Having a clean, tidy and safe work place
Keeping machines and tools in good condition
Having a say in what goes on in your cell/area
Getting things done
Making life easier – being in control
Working in a ‘smart’ way
Owning and having a pride in your machines/cell/area
Teamwork – production and maintenance
About making machines as ‘effective’ as possible

TPM® is NOT:

Operators carrying out Maintenance Engineers’ jobs
A way of making people work harder.
Employees expected to carry out tasks that they are not trained for.
A way of monitoring employees.
Extra duties in your own time.
Anything other than common sense and correct working practices.
Just a change for the shop-floor.

Operator CAN DO Activities

Bolt Tightening.
Identifying Actions
Controlling Coolant ,air leakage, muck and swarf
Calculating Machine Effectiveness
Predicting Problems.

TPM® is a registered trademark of JIPM

Keep watching this space to read Part II & Part III of this subject.

P.S. If your leaders and colleagues are also interested in this subject, do them a favor and share this link. They may thank you for your concern and initiative.

Looking for more info on Kaizen/Lean/Operational Excellence? Click here


Author: Kaizen Institute - India!

Kaizen Institute – India is part of the Global Kaizen Institute operations. Kaizen Institute was established by Sensei Masaaki Imai, the GURU of Kaizen. He wrote the 1st book 28 yrs ago and that is when it all started . We operate in 30+ countries today and have over 400+ coaches helping more then 600 organizations Learn, Apply, Sustain – Kaizen/ Operational Excellence. In India we have two physical offices – Pune & Ahmedabad and 27 coaches in all.

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