Effect of total productive maintenance tpm implementation. Since then new concepts and refinements have been added to the basic program. Total productive maintenance tpm is the process of maximizing equipment effectiveness through the active involvement of all supporting departments. This approach can reduce the waste of storing an excessive inventory of replacement parts for too long, as well as the waste of time to procure out. The goal of total productive maintenance tpm is to improve overall productivity by optimizing equipment availability. Total productive maintenance tpm was developed by seiichi nakajima based on the experience of the practical application of maintenance best practices in japan between 1950 and 1970. Lean maintenance tries to avoid wasted effort in maintenance by scheduling conditionbased maintenance test or inspect each machine, then schedule maintenance when it begins to show signs of wear. It can be considered as the medical science of machines. Total productive maintenance lean manufacturing and six. Tpm is teambased, proactive maintenance and involves every level and function in the organization, from top executives to the shop floor.
Oct 27, 2017 tpm stands for total productive maintenance. Tpm can be of great value and its target is to improve core business processes. Tpm has been identified as a best in class manufacturing improvement process, along with the lean phenomenon that has allowed manufacturing industries to greatly increase their levels of profitability and productivity. This waste is due to operators, maintenance personal, process, tooling problems and nonavailability of components in time etc. After this, a start can be made with the continuous improvement cycles.
Total productive maintenance tpm focuses on getting managers, maintenance personnel and equipment users all working together to prevent equipment problems and reduce expenditures. To start implementation of tpm firstly top management need to understand that tpm needs to be part of a long. Tpm is an acronym for total productive maintenance which is a system of coordinated group efforts for greater equipment effectiveness. Tpm total productive maintenance engages operators to improve. Outline the steps of am give practical guidance on am roll out. Continuously improving manufacturing tpm, lean and six. Find training lean and six sigma classes near you us and international. Implementing successful total productive maintenance tpm in a manufacturing plant ignatio madanhire, and charles mbohwa abstract this study examines the impact of total productive maintenance tpm implementation on an organization in terms of productivity and quality levels. In this video mike wroblewski of gemba consulting and the kaizen institute offers an overview of what total productive maintenance tpm is all about. Tpm overview page 1 tpm overview total productive maintenance, or tpm, is a method to achieve maximum equipment effectiveness through total employee involvement. Learn what total productive maintenance tpm is in this.
Implementing successful total productive maintenance tpm in a manufacturing plant ignatio madanhire, and charles mbohwa abstract this study examines the impact of total productive maintenance tpm implementation on an organization. If machine uptime availability is not predictable and product can not flow smoothly and reliably then there will be inventory and buffers must be kept to protect the customer. This is done by systematically surveying or analyzing each. Overmaintenance elimination strategy develop a deeper understanding of the true nature of the equipments failure patterns and adjust the maintenance strategy to match. Tpm introduction to total productive maintenance youtube. Total productive maintenance tpm is mostly regarded as an integral part of lean manufacturing. Equipment and tools are literally put on proactive maintenance schedules to keep them running efficiently and with greatly reduced downtime. A key aspect of lean manufacturing practices is the implementation of an. Tpmbasic, use, and ideal conditions 15 fault development 15 the basic condition 21 technical standards 24. Often preventitive measures are taken as force of habit, without considering the facts.
Applies to operators, maintenance personnel and managers. The maintenance function, particularly tpm has a vital role in converting the nonlean to lean companies. Pdf total productive maintenance tpm implementation practice. For example, let us question preventive maintenance critically. Total productive maintenance usually focusses on one piece of equipment or plant area at a time on the following losses of production and breakdowns. The goal of the tpm program is to markedly increase production while, at the same. May 26, 2015 total productive maintenance is an essential methodology to developing an organization where there is no loss of time, materials, or equipment because of breakage and shutdowns. Tpm is a critical principle for lean manufacturing.
Total productive maintenance tpm is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees that add business value to an organization tpm focuses on keeping all equipment in top working condition to avoid breakdowns and delays in manufacturing processes. Total productive maintenance tpm is a system designed to stabilize equipment performance and reliability. It blurs the distinction between the roles of production and. Total productive maintenance tpm six sigma study guide. The module starts with an explanation of lean manufacturing basics applied to maintenance as oee calculus and 7 wastes, 5s. Total productive maintenance overview the mission of each pillar is to reduce loss with the ultimate aim of elimination of all losses.
Tpm methodology implementation, change of behaviour and culture. Kaizen, total productive maintenance, tpm, lean, fertigungsme thoden, produktqualitat verbessern, innerbetriebliche prozesse ver netzen. Total productive maintenance and the basic pillars of tpm. What are the 7 pillars of tpm used in lean total productive maintenance tpm is a way of keeping and improving the reliability of manufacturing and quality systems by means of procedures, equipment, machines, and human resources that increase the value of. There is a risk that new problems are introduced instead of the equipment. This experience led to the recognition that a leadership mindset engaging front line teams in small group improvement activity is an essential element of.
Total productive maintenance tpm is a maintenance program which involves a newly defined concept for maintaining plants and equipment. The tpm training presents foundations of total productive maintenance, a system that ensures prevention and reduces machine breakdowns. Autonomous maintenance champions, production teams. Total productive maintenance tpm tpm is a powerful program for planning and achieving minimal machine downtime. By giving ownership and responsibility of equipment and processes to the right employees, equipment breakdowns are reduced. Total productive maintenance is an essential methodology to developing an organization where there is no loss of time, materials, or. Tpm improves equipment effectiveness lean production. Lean maintenance methodology the key objective of lean maintenance is to give your company the near 100% equipment uptime and reliability it demands while cutting your maintenance expense, often by 50% or more.
What are the 7 pillars of tpm used in lean latest quality. Total productive maintenance tpm summary of tpm tpm was developed in the 1970s as a method of involving machine operators in the preventive maintenance of their machines a reaction to increasing specialization and centralization of the maintenance function that had created divisionoflabor barriers between operators and the maintenance of. Total productive maintenance tpm is a maintenance program, which involves a newly defined concept for maintaining plants and equipment. The process of integrating equipment maintenance into the manufacturing process, in order to stabilize equipment, thereby increasing availability, performance and quality of the equipment. Tpm total productive maintenance lean manufacturing tpm video. Tpm total productive maintenance pdf free download. As kaizen methods evolved in the japanese automotive industry, manufacturing and total productive maintenance are the spiritual wellspring of lean philosophy which is why customers around the world value four principles deeply embedded toyota heritage and continuing affiliations so greatly.
Unites worldclass manufacturing, lean thinking and total productive maintenance tpm. Tpm total productive maintenance is a holistic approach to equipment maintenance that strives to achieve perfect production. Maintenance tbm, designout maintenance dom and total productive maintenance tpm. Autonomous maintenance is listed first in the 8 pillars of tpm and its considered as a key concept of total productive maintenance. Unexpected breakdown of a bearing on the drive motor of the jaw crusher. Engage all employees to use effective problem solving tools to make permanent and significant reduction in plant losses. Maintenance and reliability workers are always striving for perfect. The holistic approach of total productive maintenance in. Total productive maintenance, or tpm, is a holistic and comprehensive manufacturing concept that works to improve productivity by resuming defects, downtime, and speed losses while also promoting a safe and organized working environment. A requirement involves tracking tpm and usually metrics such as oee, mtbf, and mttr are applied. Tpm emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment.
This means that the concept is particularly suitable for automated andor maintenanceintensive industries. The holistic approach of total productive maintenance in lean. Making more than what is needed or making it earlier than needed reliability application. Lean tpm accelerates the benefits of continuous improvement activities within any manufacturing environment by challenging wasteful working practices, releasing the potential of the workforce, targeting effectiveness and making processes work as planned. An introduction to total productive maintenance tpm j. Manufacturers and others implementing lean practices need to understand the importance of employee involvement and support of an integrative tpm approach. Effectively and efficiently employ machinery, materials, methods and manpower through the use of lean six sigma tools. It discusses the seven steps of autonomous maintenance, a program that involves machine operators in maintenance activities. As these are supportive functions, making them understand and apply the principles of lean in their own operations makes it easy for them to provide efficient service. The maintenance pyramid a way of visualising tpm and lean maintenace. The role of tpm in maintenance is similar and comparable to total quality management tqm in quality.
Planned maintenance continuously improving manufacturing. The goal of the tpm program is to markedly increase production while, at the same time, increasing employee morale and job satisfaction. The aim of tpm is to improve productivity and reliability in production. Each operator will develop schedule for inspection based on the. Pdf total productive maintenance tpm implementation. Done correctly, tpm involves all associates including but not limited to management, operators, engineers and maintenance staff. An introduction to total productive maintenance tpm. Tpm development was first published in japan in 1982. Tpm will improve productivity by 70% and reduce complaints by approximately 60%. Tpm introduction continuously improving manufacturing. Oct 25, 2016 total productive maintenance tpm is a method of maintaining and improving the integrity of production and quality systems through the machines, equipment, employees and the supporting processes. Tpm pillarseight pillars of total productive maintenance. Total productive maintenancetpm is mostly regarded as an integral part of. Total productive maintenancetpm is mostly regarded as an integral part of lean manufacturing.
Kaizen, tpm, lean wirtschaftswissenschaften justusliebig. Performing manual oee calculations helps reinforce the underlying concepts and. Implementing successful total productive maintenance tpm in. The intention is to strengthen the requirement for equipment maintenance and overall proactive management. Introduction heightened challenges from global competitors during the past two decades have prompted many us manufacturing firms to adopt new manufacturing approaches hall, 1987. In addition to measuring oee, tpm also focuses on maintenance backlog which is also referred to as total clean out tco. Lean and tpm are commonly addressed when it comes to modern manufacturing facilities while tpm within lean tries to increment the productivity of a facility, ultimately lean philosophy targets to reduce waste. The examples below are for an ore processing plant at a mine siteunscheduled maintenance downtime breakdowns example. The integration of tpm with lean production will form a comprehensive and consistent set of manufacturing practices directed towards improved performance.
Taking tpm to the administrative functions is the next logical step in the total productive maintenance program so as to have the whole organization speaking from the same page. Implementing successful total productive maintenance. Principles of lean maintenance linkedin slideshare. The maintenance function, particularly tpm has a vital role in converting the non lean to lean companies. Tpm has an increasing role in this international automotive standard in section 8. A key aspect of lean manufacturing practices is the implementation of an integrative total productive maintenance tpm system. In todays global economy an increasing search is on for methods and processes that drive improvements in quality, costs and productivity. The primary goals of tpm are to eliminate waste caused by accidents, emergency and unscheduled downtime, defects and speed losses.
The development of maintenance systems 1 the writing technique and the contents of the book 3 the pillars of tpm 7 the toyota production system also known as lean manufacturing 12 finally, advice for using the techniques 12 chapter 1. Tpm total productive maintenance lean manufacturing. Some authors considered tpm as a lean tool but it always has been a matter of controversy. Training and education fill in knowledge gaps necessary to achieve tpm goals.
1061 1016 1311 736 1044 141 1679 1486 485 1533 975 1015 417 1527 1627 191 1213 1506 452 501 1026 1306 803 79 1101 1121 439 1261 1685 825 564 576 558 1145 36 1037 645 1011 944