TPM is a process to maximize the
productivity of your equipment for its entire life. Fostering an environment
where improvement efforts in safety, quality, delivery, cost and equipment
operating performance are encouraged, through the participation of all
employees. TPM lays emphasis on, Total profit management-company survival,
Total production management-ISO, JIT, TQM, Total perfect management-loss elimination,
Total productive maintenance & management and Total productivity management
TPM is a manufacturing led
initiative that emphasizes the importance of people, a 'can do' and 'continuous
improvement' philosophy and the importance of production and maintenance staff
working together. It is presented as a key part of an overall manufacturing
philosophy. In essence, TPM seeks to reshape the organization to liberate its
own potential.
Prime goals of TPM
ü To Maximize Overall Efficiency
Company’s prime objective to take
production efficiency to its limits pursuit of Economic Efficiency
ü To Establish a Total Preventive Maintenance for Entire Life Span Of the Machine
Prevent Losses
Before Occur – Throughout the entire production system’s Life Zero Defects, Zero Accidents, and Zero Breakdown
ü Participation by All Departments (Operation –
Planning- Maintenance – Sales- etc...)
ü To
Keep Equipment in Optimal Condition, Visual Control, Clean Area.
ü To
Promote Plant Maintenance by Motivation
Management through Autonomous Small Group Activities (SGA)
ü It reduce the life span cycle of machine
expenditure
Need for TPM
ü To maintain and improve equipment capacity and
efficiency.
ü
To
maintain equipment for a lifespan.
ü
To
co-ordinate and to get support all operating areas.
ü
Encourage
input from all levels of employees.
ü
Forming a
separate team for continuous improvement.
ü
To implement management systems in all levels of
department for ordination and cooperation
ü
To build organisation culture in order to
maximize of production efficiency and to increase profit
Eight pillars of TPM
1. AUTONOMOUS MAINTENANCES
In this
pillar, development of operators for handle initial maintenance requirements
and tasks which are regular required for maintain smooth operations. Hence the
maintenance peoples can divert and send time on more value added activities and
technical maintenance. In this concept focus on, each equipment operator is
responsible, for maintain and prevention of its equipment.
This can be
done by Educate employee, Initial Cleaning, General Inspection, Standardization, and Checklist.
2. EQUIPEMENT IMPROVEMENT / FOCUSED MANAGEMENT
Focused improvement is the initial pillar of total
productive maintenance system, it is focus on improvement on the whole system,
through identify and eliminate losses by team approach. Organizational complex
issues can possible through implementation of focused improvement step,
generally this pillar follows a structured system support of PDCA cycle to
identify and eliminate issues b systematic way. In this pillar you have to
establish an analysis of the different type of losses affecting the existing
system and manufacturing activities, and strategic management to determine
criteria for targeting issues and losses. For making every employee to be
self-sufficient in solving an appropriate issue, as well develop the
capabilities of the team, and the pillar ensures that the manpower has the
skills and motivation to identify and reduce issues from their processes.
3. PLANNED MAINTENANCE
Objective of this pillar is to establishment of the
predictive maintenance system for equipment and related tooling materials, as
well as try it should have achieved the natural life cycle of each equipment
elements. To achieve goals such as zero break downs, prevention of equipment
and predictive system are possible through planned maintenance which is third
pillar of total productive maintenance.
4. QUALITY MANAGEMENT
Quality management is defined as a procedure for control the
condition of machinery and equipment elements that directly or indirectly
negative impacts in quality of products during manufacturing processes. To
achieve purpose of zero defects by help and maintain equipment condition needs
to setup error proofing system in manufacturing facility to prevent mistakes
from happening in initial stage & root cause analysis to identify real
cause, to fix it immediately and permanently.
5. EDUCATION ANDD TRAINING
The purpose of this pillar is to establishment of education
& training for equipment operators and maintenance personnel for technical,
and system that drive total productive maintenance activities. Probably, total
productive maintenance system is a continuous learning process hence all the
related personnel must activity participate and learn through complete
associated tasks
6. SAFETY AND ENVIRNOMENT
From the planning to sustain of total productive maintenance
activities, safety & prevention of adverse environmental impacts should be
on priorities. And should make the aim to be establish system to target zero
accident, zero health damage and zero fires incidents. This pillar is playing
important role at every stage of the Total productive maintenance, and assuring
that the total productive maintenance activities are not violate safety
system's requirements.
7. INTIAL CONTROLS/EARLY MANAGEMENT
The aim of the early management is process for establish
system for reducing the time for new product or equipment development start up
time, commissioning time, and stabilization time with highly expected quality
product setup. It works based on maintenance reports, team leaders anticipate
and plan for parts and equipment lifecycles and report to managers. The basic
idea behind this is to improve the overall equipment efficiency.
8. OFFICE TPM
The purpose of the pillar office TPM is to achieve zero
function losses, establishment of efficient offices, and implementation of
service support functions for manufacturing processes. Administrative and
support team works in the total productive maintenance system as collection,
processing and distribution of information for process analysis and flowing the
required information at various stages of total productive maintenance system.
Six Major Losses to Overcome Using TPM
O.E.E. (Overall Equipment
Effectiveness) is used to identify and attack what are called the Six Major
Losses. These losses are the most common causes of lost time and
efficiency of production equipment.
1. Breakdowns and Failures
It is a loss of equipment function
needed to perform a operation.
Causes:
Ø Overloading
the machine
Ø Loose
bolts and nuts
Ø Excessive
wear
Ø Lack
of oil
Ø Contamination
2. Set-up and Adjustments
It is the
time lost during changeover from the current product to the next product, or
changing the settings during a run.
Causes:
Ø Remove
tooling
Ø Find
tooling
Ø Attaching
new tooling
Ø Adjust
new settings
3. Idling and Minor Stop
Brief
stoppages are due to 'insignificant' problems.
Causes:
Ø Parts
stuck in a chute
Ø Removing
chips
Ø Malfunction
of sensors
Ø Program
error
4. Reduced Speed
These are
loss when machine operates below design standard speeds.
Causes:
Ø Machine
wear
Ø Human
intervention
Ø Tool
wear
Ø Overloading
machine
5. Defects
Time lost to making scrap, doing rework, or managing
defective parts.
Causes:
Ø Manual
error
Ø Bad
material
Ø Tool
breakage
6. Startup and Yield
Time it takes a machine to 'warm up' to full production
after a period of downtime.
Causes
Ø Slowly
bringing machines up to speed
Ø Raising
ovens to set temperature
Ø Running
off excess material & Process
related loss of material
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