Globalization has made the business much more competitive. These days, in order to remain competitive, companies cannot afford un necessary wastes, unnecessary machine down time, accidents and product rejections. That’s why in this competitive environment, manufacturing companies are moving towards zero waste, zero machines down time, zero accident and higher production rates. In this scenario, concept of Total Productive Maintenance (TPM) is being widely adopted by many manufacturing, service and maintenance organizations.
TPM is defining new concepts of maintaining the machines and equipments. Goal and target of this tool is to minimize, unscheduled and emergency maintenance to a minimum level.
History of TPM is bit controversial. Some people argue that American Manufacturer gave the concept of TPM in 1960’s. Other argues that Japanese manufacturers gave this concept in 1950’s. Some say that concept of TPM started when, Preventive maintenance started in Japan in 1950’s. Concepts of TPM started to flourish in 1980’s and in 1990, a conference was held in USA about TPM. Today, a number of conferences are being conducted to popularize this concept of TPM and many companies are offering training programs and consultancy services.
Typical benefits of TPM implementation can be:
•Increased Production rate
•Fewer Defects
•Increase in Labor Productivity
•Employee Empowerment
•Fewer Breakdowns of Machine
•Fewer Short Stoppages
•Reduction in production related Costs
•Reduction in production related Wastes
•Overall equipment effectiveness
•Satisfied customer
TPM main targets are:
•Reduction in Manufacturing cost by 30
•Accident free environment
•Operating machine during tea and lunch break
•Minimum 90 Overall Equipment Efficiency (OEE)
Pillars of TPM
TPM concept is based upon following 08 pillars:
1.5S is systematic method of housekeeping and is also baseline for TPM implementation. It is Japanese term used for five words, meaning Sorting, Setting in order, Shining, Standardizing and Sustaining.
2.Autonomous Maintenance concept is used to empower machine operator to carry out routine maintenance activities, and maintenance personnel are involved in major maintenance activities.
3.Kaizen is combination of two words, Kai and Zen. Kai means to modify or changes and Zen means make good or better. So, as a whole it is to change something for betterment or goodness.
4.Planned Maintenance is used to prevent machine/equipment failure and ultimately minimizing production of wrong products. It is breakdown in four groups:
5.Quality Maintenance is maintaining machine or equipment in such a way that they produce error free quality products.
Training is an integral part of TPM. This focuses on training people to from know how concept to know why concept and then they can perform routine preventive maintenance activities. Training is also imparted to enhance their level of motivation and confidence level for performing their job in an effective manner.
6.Office TPM is used to improve productivity and losses in office related work like administration, accounts and finance etc.
7.Safety Health and Environment is an important tool, which focuses on zero accident, zero fire and zero human health damage. Work and processes are designed in such a way that they might not affect workplace safety.
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