This is accomplished by developing teams that involve everyone with the purpose of insuring that small equipment problems are quickly identified and corrected before they cause significant losses due to downtime or defective product.
When and How to use it?
Implement TPM to reduce firefighting by improving reliability and performance of equipment. it should be the goal of every company to deliver high quality products or services to the customer on time. In order for the operation to truly be considered lean, equipment must consistently and reliably produce high quality output at the necessary rate. One of the features that differentiates TPM from simple preventive maintenance is that its objetive is not only to prevent breakdowns, but to do so using the most efficient and economical methods.
Use TPM to extend and improve existing preventive maintenance programs. Traditional maintenance programs typically rely on mechanics or other specialist to maintain and repair broken equipment. TPM recognizes that equipment operators are continually in contact with their machines. The allows them to detect small changes in the performance or behavior of the equipment which often signal the onset of a problem. Operators can proactively address many of these small issues and can provide early warning of problems that require specialized skills to correct.
Although the complexity of existing maintenance programs varies from one company to another, the implementation of a full TPM program typically includes some or all of the 14 following steps.
- Select a pilot Project
- Form a Team
- Define the current state
- Calculate current Overall Equipment Effectiveness
- Rank sources of performance loss
- Conduct a 5s exercise
- Clean and inspect equipment
- Create an equipment history log
- Provide operators with specialized training
- Establish standards for routine maintenance
- Use visual controls to prevent errors
- Identify and correct root causes of issues
- Address recurring problems
- Sustain improvements
As Helpful Hints
- Don´t Accept that there`s no time to do TPM because. "We´re too busy". TPM does´t take time, it saves it.
- Use success stories from one area to promote activity or benefits in another area. Place "Lessons Learned" posters on bulletin boards to transfer "Best practice" or to "Spark" new ideas.
- Recognize and reward success.
- Remember TPM is a form of continuous improvement. It is an iterative process that is never entirely complete
