Total Productive Maintenance (TPM) in Lean Manufacturing.

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Total Productive Maintenance (TPM) in Lean Manufacturing.

Total Productive Maintenance (TPM) in Lean Manufacturing -

  • Total Productive Maintenance (TPM) in Lean Manufacturing is a maintenance philosophy designed to integrate equipment maintenance into the manufacturing process for losses elimination due to equipment and keeping equipment with no or less downtime resulting in improved productivity.
  • The process of Total Productive Maintenance (TPM) in Lean Manufacturing is change from corrective maintenance, preventative maintenance, predictive maintenance.
  • TPM is reducing or eliminating production time loss due to machine failures and keeping equipment available to manufacture products for all time.
  • Successful TPM is a group effort where the entire organization works together to maintain and improve the equipment. 
  • The first steps in implementing Total Productive Maintenance (TPM) in Lean Manufacturing is team formation to improve the process. 
  • Employees join TPM teams.
  • Operators are trained to perform routine maintenance and given an ownership role.
  • Employees would have normally been overlooked by management.
  • To measure the success of TPM programs,the term OEE (Overall Equipment Effectiveness) is developed.
  • OEE helps the  organizations to monitor the progress with simple and easy to understand metrics.


BIG LOSSES SUFFERED IN AN MANUFACTURING INDUSTRY-


LOSSES RELATED TO EQUIPMENT -

1. Breakdown loss:

Examples: Bearing failure, Belt failure, Proximity failure etc.

2. Cutting blade replacement loss:

Examples: Replacement of saw blades, grinding tools, lathe tools etc.

3. Start-up loss:

Examples: Warming or cooling of equipment to operating temperature.

4. Set up & adjustment loss:

Examples: Changeover of die or product.

5. Minor stoppage & idling loss:

Examples:  Home positioning, Hydraulic pressure development at start, Waiting for a machine to index for tool positioning etc.

6. Defect & rework loss:

Examples: Out of specification product, poor surface finish, incorrect labelling.

7. Speed loss: 

Examples: Line speed reduced due to quality issues, mechanical problems etc.

8. Shutdown loss:

Examples: Routine maintenance, Machine cleaning, Periodic overhaul etc.

LOSSES RELATED TO MANPOWER-

9. Management Loss:

Examples: Failure to supply raw materials, Failure to provide spare parts, Failure to provide  manpower resource, Failure to provide utilities.

10.Motion loss-

Examples: Walking loss, wasted motion like unnecessary lifting.

11. Line Organisation Loss:

Examples: No additional cover or contingency for break times.

12. Distribution Loss:

Example: Incorrect delivery of materials from supplier to store,  excessive handling of deliveries (double handling), late deliveries etc.

13. Measurement and Adjustment Loss:

Example: Measurement loss is experienced when excessive inspection integrated in the process as a result of poor quality.Adjustment loss is experienced when adjusting equipment back to the standard after routine cleaning and periodic consumable changes.

LOSSES RELATED TO RESOURCE CONSUMPTION-

14. Yield Losses: 

Examples: over-pack, giveaway, mass balances.

15. Energy Losses:

Examples: Start-up losses, Idling losses. 

16. Die, Tool and Jig Losses:

Examples: Cost of spares, cost of replacement and maintenance to tooling, dies and jigs.


EFFECTIVE TPM ELIMINATES/ 5 WASTES/LOSSES-

1.Equipment Breakdowns.

2.Defects / Scraps / Reworks.

3.Safety Issues.

4.Minor Stoppages.

5.Reduced Speed.

12 steps in implementing Total Productive Maintenance (TPM) in Lean Manufacturing -

1.Announce top management's decision to introduce TPM. 

2.Launch education & campaign. 

3.Create organisation support structure to promote TPM.

4. Establish basic TPM policies & goals. 5.Formulate master plan.

6.Hold TPM kick - off.

7.Improve equipment effectiveness. 

8.Develop autonomous maintenance programme. 

9.Develop scheduled maint program.

10.Conduct training. 

11.Develep early equipment management program. 12.Perfect TPM implementation & raise TPM levels.


FIVE FUNDAMENTAL ACTIVITIES OF TPM-

1.Autonomous Maintenance.

2.Equipment Improvement.

3.Quality Maintenance.

4.Maintenance Preventing System Building.

5.Education & Training.


8 PILLARS OF TPM-

1.Autonomous Maintenance.

2.Focused Improvement.

3.Planned Maintenance.

4.Quality Maintenance.

5.Education & Training.

6.System of 5S.

7.SHE (Safety Health &  Environment).

8.Office TPM.

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