TPM 8 Pillars and its outcome

This post is about TPM eight pillars and its outcome while we are following.

TPM (Total Productive Maintenance) is an approach by getting a operators involved in maintaining their own equipment that strives to achieve perfect production:

  • No Breakdowns
  • No Small Stops or Slow Running
  • No Defects

By doing this it leads to

  • No Accidents.

5s plays a major part in TPM.Is is the base foundation of TPM.The implementation of a TPM program creates a shared responsibility for equipment that encourages greater involvement by plant floor workers. In the right environment this can be very effective in improving productivity

  • Increasing up time,
  • Reducing cycle times,
  • Eliminating defects.

The Eight Pillars

The eight pillars of TPM are mostly focused on proactive and preventative techniques for improving equipment reliability.

Pic Courtesy:http://www.shaktimanagro.com/tpm/

Autonomous Maintenance:

            Places responsibility for routine maintenance, such as cleaning, lubricating, retightening (CLRI) and inspection, in the hands of operators.

OutCome:

  • Gives operators greater “ownership” of their equipment.
  • Increases operators’ knowledge of their equipment.
  • Ensures equipment is well-cleaned and lubricated.
  • Identifies emergent issues before they become failures.
  • Frees maintenance personnel for higher-level tasks.

 Planned Maintenance:

            Schedules maintenance tasks based on predicted or measured failure rates.

OutCome:

  • Significantly reduces instances of unplanned stop time.
  • Enables most maintenance to be planned for times when equipment is not scheduled for production.
  • Reduces inventory through better control of wear-prone and failure-prone parts.

Quality Maintenance:

            Design error detection and prevention into production processes. Apply Root Cause Analysis to eliminate recurring sources of quality defects.

OutCome:

  • Specifically targets quality issues with improvement projects focused on removing root sources of defects.
  • Reduces number of defects.
  • Reduces cost by finding defects early (it is expensive and unreliable to find defects through inspection).

 Focused Improvement:

            Have small groups of employees work together proactively to achieve regular, incremental improvements in equipment operation.

OutCome:

  • Recurring problems are identified and resolved by cross-functional teams.
  • Combines the collective talents of a company to create an engine for continuous improvement.

Early Equipment Management:

            Directs practical knowledge and understanding of manufacturing equipment gained through TPM towards improving the design of new equipment.

OutCome:

  • New equipment reaches planned performance levels much faster due to fewer startup issues.
  • Maintenance is simpler and more robust due to practical review and employee involvement prior to installation.

Training and Education:

            Fill in knowledge gaps necessary to achieve TPM goals. Applies to operators, maintenance personnel and managers.

OutCome:

  • Operators develop skills to routinely maintain equipment and identify emerging problems.
  • Maintenance personnel learn techniques for proactive and preventative maintenance.
  • Managers are trained on TPM principles as well as on employee coaching and development.

 

Safety, Health, Environment:

            Maintain a safe and healthy working environment.

OutCome:

  • Eliminates potential health and safety risks, resulting in a safer workplace.
  • Specifically targets the goal of an accident-free workplace.

 

TPM in Administration:

            Apply TPM techniques to administrative functions.

OutCome:

  • Extends TPM benefits beyond the plant floor by addressing waste in administrative functions.
  • Supports production through improved administrative operations (e.g. order processing, procurement, and scheduling).