Pillars Of TPM (Total Productive Maintenance) in Lean Manufacturing.

By -

Total Productive Maintenance (TPM) is maintaining and improving production and quality through the man, machine & processes to add value to an organizational growth.

There are eight Pillars of TPM (Total Productive Maintenance) in Lean Manufacturing


Pillars of TPM (Total Productive Maintenance) in Lean Manufacturing are useful in improvement of the machines reliability.


8 Pillars of TPM


Eight Pillars of TPM (Total Productive Maintenance) in Lean Manufacturing are listed as -

1.Autonomous Maintenance

(Jishu-Hozen)

2.Focused Improvement 

(Kobetsu-Kaizen).

3.Planned Maintenance 

(Keikaku-Hozen)

4.Quality Maintenance

(Hinshitsu-Hozen)

5.Early Equipmemt Maintenance (EEM) & Five S's (5S)

6.Education & Training

(E&T)

7.Safety Health & Environment (SHE)

8.Office TPM.


Eight Pillars of TPM (Total Productive Maintenance) in Lean Manufacturing are explained in brief as follows-


1. AUTONOMOUS MAINTENANCE (JISHU-HOZEN) -

Targets -

  • To reduce Oil Consumption by 50%.
  • To reduce Process Time by 50%.
  • To increase Operator Knowledge about equipment.
  • To increase Worker's Skill Levels.
  • To free the Maintenance personnel for higher level or special assignments. 
  • To increase Machine Life through constant monitoring and maintenance.

Tools used -

  • Initial Cleaning by operator as a Machine Owner.
  • Cleaning & Lubricating by Operator.
  • Lubrication Standards.
  • Countermeasure at the source of the problem.
  • General Inspection by operator.
  • Identify and Eliminating the wastes.
  • Minor Maintenance Activities  by Operators.
  • Full Autonomous Maintenance (OEE,OPE,PDCA)



2.  FOCUSED IMPROVEMENT (KOBETSU-KAIZEN)-

Targets -

  • To achieve Zero Losses due to downtime & minor stoppages.
  • To improve OEE.
  • To reduce manufacturing cost.

Tools Used -

  • Kaizen Summary Sheets.
  • Kaizen Register.
  • Why-Why Analysis.
  • Bottleneck Identifications and Targets Setting.
  • Calculations of OEE.
  • Analysis of OEE.
  • Projects Launching.
  • Education & Trainings.

Features -

  • Incremental or continuous Improvement process.
  • Helping for quality and productivity improvement by identifying, analyzing and eliminating Non-Value Added work.
  • Kaizen Teams formation with people from various departments as a collective talents.
  • The problems related to equipment are identified  by Kaizen Teams.
  • Improvement goals are set in Kaizen Event.
  • The Kaizen Team analyses the root cause of the problems , implements solutions and ensures sustainability.


3. PLANNED MAINTENANCE (KEIKAKU-HOZEN) -

Targets -

  • To reduce Maintenance Cost.
  • To reduce Spare-Parts Inventory.
  • To achieve Zero Breakdown Cost.
  • To improve Maintainability and Reliability of equipments.

Tools Used -

  • PM Schedule Preparations.
  • Operator Training with One-Point Lesson.
  • Education and Training of JH Teams.

Features -

  • Planned maintenance before the machine breaks down to reduce unplanned stop times.
  • Planning the Equipment Maintenance with respect to the machine failure rate.
  • Planned maintenance to be carried out with prior information to Production Team.
  • Production peoples are allowed to built up some inventory before planned maintenance.



4. QUALITY MAINTENANCE (HINSHITSU-HOZEN) -

Targets -

  • To reduce numbers of process defects.
  • To catch defect early or at the source.
  • To achieve Zero Customer Complaints.
  • To improve quality by ensuring ability of equipment to detect and prevent errors during inline production. 
  • To make processes reliable to produce the right components at the first time.
  • To reduce the Cost of Poor Quality (COPQ).
  • To release the operators from the tedious monitoring on quality.
  • To implement Poka-Yoke for elimination of human errors.

Tools Used -

  • Field Complaints.
  • Customer endline rejection.
  • Root Cause Identification through Why-Why Analysis.
  • Inspection Standards based on product & process related data.
  • Design correction for product & process.
  • Auditing Countermeasures and Standards periodically.
  • Poka-Yoke implementation.


5. EARLY EQUIPMENT MAINTENANCE (EEM) & 5S-

Targets -

  • To help to design equipment easy to operate and maintain.
  • To build in high efficiency from the design stage of the equipment.
  • 5S implementation.

Features -

  • Equipment is Fulfilling the autonomous maintenance standards.
  • Guaranteed productivity and quality of the equipment from the start of it's commissioning.

Factors considered in EEM -

  • Ease of cleaning, lubrication and inspection.
  • Accessibility of equipment parts.
  • Make the machines easier to operate (Ergonomic aspects).
  • Making it easier for the change-over (Easy clamping, Quick adjustment settings, etc)
  • Feedback mechanisms to alert defective products (Visual Indicators).
  • Increased safety features.


6. EDUCATION & TRAINING 

(E & T) -

Skill Matrix -

1.Do not know.

2.Knows but Can't Do.

3.Can do but Can't Teach.

4.Can Do and Can Teach.

Targets -

  • To raise Operators’ skills levels in such a way that they could carry out basic maintenance activities. 
  • Preventive maintenance and analytical skills helps maintenance personnel in problem solving.
  • Managers becomes competent mentors for the operators after learning of TPM skills.
  • To build Competence of each member for productivity improvement.

Tools Used -

  • Soft Skills Training.
  • Technical Skills.
  • Communication Skills.

Features -

  • Education and Training is a initiative of the organization involving operators to senior managers level.



7. SAFETY, HEALTH & ENVIRONMEMT 

(SHE) -

Classification of Accidents-

1.Major Reportable Accidents.

2.Medium Non-reportable Accidents.

3.Minor Accidents.

Targets -

  • To achieve Zero Accident.
  • To create safe workplace.
  • To ensure that all workers are provided the safe and hazzard free workplace.
  • To eliminate the unsafe conditions.
  • To improve the safety of the machines for workforce by putting in place machine guards, Standard Operating Procedures (SOP), use of personal protective equipment (PPE) and first-aid kits in the work area. 

Tools Used -

  • SHE guidance.
  • Use of PPE's.

Features -

  • Employee's attitude towards work changes dramatically resulting in productivity and Quality improvements.
  • The teams will work towards making machines safe to use for the operators.


8. OFFICE TPM -

Major Losses in Office -

  1. Processing loss.
  2. Communication loss.
  3. Accuracy loss.
  4. Office Equipment Breakdowns.

Targets -

  • To reduce admin cost, overhead cost and inventory carrying cost.
  • To reduce number of files and repeative work.
  • To provide efficient service to the Value Added work.
  • To support production by administrative work like processing of order, Scheduling, Procurement etc.

Members -

  • Administrative Team, Management.

Features -

  • Management and administrative departments are also plays role in productivity improvement.


BENIFITS OF TOTAL PRODUCTIVE MAINTENANCE (TPM)-

  1. Significantly decreased  Equipment Maintenance Cost and less unplanned maintenance.
  2. Reduced equipment downtime & Increased equipment availability and profitability.
  3. Providing the tools to turn maintenance programs into a competitive advantage lowering the Maintenance Cost.
  4. Improved teamwork and employee involvement and Strengthened Workplace Safety.

#

Comments

Post a Comment

MOST POPULAR

Basic Work Content And Productivity Improvement.

By -
Factors Affecting Basic Work Content -   Basic work content is the minimum time required for production as per standard rate of working with the help of qualified worker and with perfect design and specifications. The heart of the productivity improvement in any manufacturing organisation is depend on its basic work content. Process of manufacturing is affected by some factors associated with basic work content. Following are the factors affecting basic work content and thus on the productivity. 1.Workmen Efficiency: Workmen enfluencing basic work content in following ways-  Careless workemenship  Accidents by workmen. Absentism of workmen. Idleness of workmen. Lateness of workmen. Indisciplined workmen.   2.Management Shortcomings: Management is also responsible for enfluence on basic work content . Some management shortcomings are as - Design changes. Excess product variety Bad planning. Lack of standardization. Plant Breakdowns.   Bad working conditions...
Read more

SMED

By -
SMED: SMED (Single Minute Exchange of Die): SMED  stands for  Single Minute Exchange of Die. SMED (Single-Minute Exchange of Die)  is a Lean tool used in manufacturing to reduce equipment changeover time.  The goal of  SMED  is to complete as many steps as possible while the equipment is running , to save time and quickly change over to processing the next product. The core principles of the  SMED  procedure involve separating changeover elements into two categories. Internal activities and External activities. For  SMED : Internal activities  -  can only be performed when the production process is stopped. External activities-  can be completed while the machine running or upto the actual changeover begins.  SMED  helps in achievement of  rapid setups and minimized downtime by  converting internal activities into external activities. Advantages of the SMED: Reduced changeover times / Reduced Downtime by min...
Read more

5S What is 5S ?

By -
5S : 5 S's meant for: 1st  S - Seiri means Sort. 2nd S - Seiton means Set in Order. 3rd S - Seiso means Shine. 4th S - Seiketsu means Standardize. 5th S - Shitsuke means Sustain. THE GOAL OF 5S - To create a clean and well-organized work environment for ease of operation. To reduce waste, to improve quality. To promote safety. To Encourage people for addressing problems  resulting in a positive change to the organizational culture.  For the quick set-ups in clean and well organized workplace. To improve equipment reliability. THE ELEMENTS OF 5S  - 1. SEIRI (SORT) -  Elimination of things that are not really needed at the work place. 2. SEITON (SET IN ORDER) -  Systematic Organization of the items remained after sorting. 3. SEISO (SHINE) -  Sanitizing ,Cleaning and Inspection of the work area. 4. SEIKETSU (STANDERDIZE) -  Standardization that means to create Standards. 5. SHITSUKE (SUSTAIN) - Self descipline that is ensure the regular application ...
Read more

PPE (Personal protective equipment)

By -
PPE : PPE full form : Personal Protective Equipment. PPE means Personal Protective Equipment. Personal protective equipment (PPE) refers to protective clothings, helmets, gloves, face shields, goggles, facemasks, earplugs, muffs, coveralls, vests, full body suits,  high visibility suits, safety harnesses, respirators or other equipments designed for protection from injury ,infection, illnes or exposure to a variety of hazards. Why PPE: To promote good Hygiene To prevent Hazards To reduce spread of infection To enhance workplace safety To protect Lives   To comply businesses with regulatory requirements(e.g., The Personal Protective Equipment at Work Regulations 1992) To improve employee efficiency. Types of Protection: 1) Respiratory Protection: Protection against the adverse health effects caused by breathing contaminated air. Examples:Respirators. 2) Eye & Face Protection: Eye and face protection from the hazards of  hot sparks, and chemical splashes  flyi...
Read more

JIT and Advantages Of JIT (Just In Time) Manufacturing.

By -
JIT and Advantages Of JIT (Just In Time) Manufacturing: JIT (Just In Time) manufacturing is very benificial for lean manufacturing. The benifits of JIT for manufacturing industries are a lot. Some of the advantages of JIT in manufacturing are as follows- Lesser Cost Of Production. Less working capital is required to finance for procurement.  Minimum re-order level. Works on a demand-pull basis, in the volatile and unpredictable market demand. Inspection costs and Rework costs are minimized. High customer satisfaction due to constant communication with the customer. Reduction in Manufacturing Lead Time and Increased Conformance to Delivery Lead Time. Reduction in Inventory Investment and Increased Investment Savings. Increased Revenue and High ROI (Return On Investments). Increased Response Speed to Market Needs. Close relationships and Improved Workforce Morales. Uncovering of Problems. Keeps stock holding costs minimum and better space utilization with Low or No warehousing cost. ...
Read more

Total Quality Management (TQM)

By -
WHAT IS TQM ? (Total Quality Management) 1. TQM is the management approach for the organization which aims for the continuous improvement in the products and services for the customer satisfaction with all employee involvement as the whole and taking into consideration the quality at center as the way for long term success of organization and improvement of the employees. 2. TQM is the Quality improvement with continuous efforts ,systematic analysis and improved work processes. THREE THEMES OF TQM - 1.The Customer 2.The Process 3.The Employees. PRIMARY ELEMENTS OF TQM- 1.Customer Focused. 2.Total Employee Involvement. 3.Process Centered. 4.Integrated System. 5.Strategic & Systematic Approach. 6.Fact Based Decision making. 7.Continual Improvement. 8.Communication LEADERS OF TQM- I MPORTANCE OF TQM - #Customer satisfaction #Team building #Reduction in customer complaint #Reduction in rejection rate #Helps to face competition #Better motivation to employees #Better facilities to emplo...
Read more

Lean management in COVID-19 vaccine production.

By -
L ean management in the pharmaceutical industry and COVID 19. The pharma companies manufacturing the vaccine for  Covid-19 has to follow strictly the lean manufacturing principles to eliminate non value added work so as to achieve the demand raised in this panademics of COVID-19 . For the organizations like Serum Institute of India, Lean Manucturing tools will help to do value added acts every time so as to meet the demand of vaccine in India and other countries. On time and quality production of vaccine with reduced associated costs will help the organizations like SERUM & PFIZER to meet the expectations of people of the whole world's  and high demand. Also Lean tools will results in reduced prices of the vaccine. The pharma industries must achieve Zero Losses due to downtime & minor stoppages so as to meet the demand of vaccine. Reduced manufacturing cost is going to help to provide the vaccine to the Governments with reduced cost and so the distribution amongst the ...
Read more

Industrial safety

By -
Industrial safety - Industrial safety  leads to ZERO ACCIDENT GOAL   of every organisation. Everyone working in the industries must follow Industrial safety rules. Creating and maintaining protective, safe and efficient workplace environment is the major role played by Industrial safety Management team. Workplace safety is very important for each and every employee to work in a safe and protected atmosphere. What is meant for term  safety  in  Industrial safety? Safety means a state of being safe from the risk of loss or danger. Safety plays a vital role in industry by protecting employees and assets by minimizing hazards, risks, accidents, and near misses. Safety is a condition that gives you freedom from hazards, risks, and accidents that may cause injury, damage, loss of material or property damage, and even death. Elimination of hazard is also known as safety.  Safe and healthy workplace protects workers from injury and illness which reduces absen...
Read more

Kaizen-The Japanese Methodology

By -
Kaizen-The Japanese Methodology: Kaizen is a Japanese word. Kaizen is the Japanese methodology used in lean manufacturing techniques. Kaizen means good change or "Continuous Improvement" .  Kaizen is a  method for improving processes with small but incremental changes over time. Kaizen Benefits: to eliminate waste. to optimize efficiency. to improve quality. to empower employees . Kaizen is a method to encourage employees to work together to make small but regular improvements in business processes. Kaizen is a Japanese  philosophy that encourages continuous improvement by  all employees involvement.It is a long-term approach to small but incremental improvements. 5 in Kaizen or Steps in Kaizen technique: 1)Identifying problems 2)Analyzing the current process 3)Brainstorming the solutions and selecting the best solution. 4)Implementing the best solution into practice 5)Reviewing the results and Standardizing the solution as a part of ongoing processes. ORIGIN OF KAIZ...
Read more

Bottleneck in production process.

By -
BOTTLENECK IN PRODUCTION PROCESS- Bottleneck in production process , is a process whose limited capacity reduces, delays or stops the flow of operation and affects the capacity of overall manufacturing processes.   Almost every system has a bottleneck . The machine with the longest queue of accumulated input for processing is usually a bottleneck in production process. It is important to identify the bottleneck machine or process and to remove or reduce the waiting time for next operation so as to achieve the desired targets in manufacturing processes. Here discussed the various types of   bottleneck in production process. Types of Bottleneck in production process: 1.Short-term Bottleneck:  These are caused by temporary problems.  Short-term bottlenecks  do not need regular attention. 2.Long-term Bottleneck:   Long-term bottlenecks occur all the time. These have substantial impacts on the overall manufacturing processes.  Long-term bottl...
Read more