Four Principles TPM

Summary

Total Productive Maintenance (TPM) is a comprehensive approach to enhancing manufacturing efficiency by integrating preventive maintenance, total quality control, and employee involvement. It involves creating a database for equipment maintenance, standardizing processes, and conducting planned maintenance to reduce breakdowns and improve machine performance. TPM ensures a clean and safe work environment, with employees responsible for equipment upkeep. By monitoring key process indicators, TPM promotes continuous improvement, leading to reduced downtime and increased productivity.

Takeaways

• 🔧 TPM stands for Total Productive Maintenance, which is a lean approach to improving the manufacturing process.
• 👷 TPM combines preventive maintenance with total quality control and total employee involvement.
• 🚫 The traditional 'fix it when it breaks' approach can lead to significant downtime and larger problems.
• 📈 TPM focuses on eliminating major equipment-related losses to improve overall efficiency.
• 📚 TPM involves creating a comprehensive database for each piece of equipment to guide maintenance.
• 🛠️ Employees are trained to understand what, when, and how to maintain equipment based on the database.
• 🔄 Standardization of processes is key, including setting key parameters and training on identifying losses.
• 📅 Planned maintenance is scheduled to maintain each part of the machine at recommended intervals.
• 🧹 Keeping equipment clean is part of TPM, helping to detect failures early and avoid breakdowns.
• 🔄 TPM includes a continuous improvement process with key process indicators monitored and managed.
• 💼 TPM leads to reduced breakdowns, improved machine speed, and quality, with efficient systems in place.

Q & A

What is Total Productive Maintenance (TPM)?

TPM is a lean approach to improving the manufacturing process by combining preventive maintenance with total quality control and total employee involvement.

Why is TPM important for a business?

TPM is crucial as it helps eliminate major equipment-related losses, reduces breakdowns, improves machine speed and quality, and ensures efficient operations even when issues arise.

What are the four principles of TPM mentioned in the script?

The script does not explicitly mention four principles but outlines seven pillars for a practical and sustainable TPM approach.

What are the seven pillars of TPM?

The script does not detail each of the seven pillars but implies they involve equipment history knowledge, standardization, planned maintenance, cleanliness, spare parts analysis, trial standard operating procedures, and continuous improvement.

How does TPM help in maintaining equipment?

TPM helps by building a database for each piece of equipment, providing employees with the skills to maintain equipment correctly, and scheduling routine maintenance to improve machine performance.

What is the significance of knowing equipment history in TPM?

Knowing equipment history allows for the creation of a database that eliminates guesswork, ensuring employees know exactly what to maintain, when, and how long it will take.

How does TPM approach the issue of machine cleanliness?

TPM includes keeping equipment clean as part of its procedure, where each team member is responsible for a clean, safe work environment. Regular cleaning can detect failures early, preventing sudden breakdowns.

What role do spare parts play in TPM?

TPM involves analyzing spare parts based on consumption and past purchases to ensure that parts that wear out often are always accessible.

How does TPM address machine breakdowns?

TPM reduces the occurrence of machine breakdowns through planned maintenance and continuous improvement processes, ensuring that when issues do arise, there is minimal downtime and wasted resources.

What is the 'pit-stop approach' mentioned in the script?

The 'pit-stop approach' refers to a method of trialing standard operating procedures where what works and what doesn't is analyzed, and key process indicators are monitored for continuous improvement.

How does TPM involve total employee involvement?

TPM involves all employees by assigning responsibility for maintenance and cleanliness, providing training on process measurement and loss identification, and encouraging a culture of continuous improvement.

Outlines

00:00

🔧 Introduction to Total Productive Maintenance (TPM)

The paragraph introduces the concept of Total Productive Maintenance (TPM) as a solution to the problem of machines breaking down due to lack of routine maintenance. It emphasizes the importance of TPM, which is a lean approach to improving the manufacturing process by combining preventive maintenance, total quality control, and total employee involvement. TPM is not just for maintenance staff or to improve machines cosmetically, but it's an organization-wide strategy aimed at eliminating equipment-related losses. The paragraph outlines four principles and seven pillars for a practical and sustainable TPM approach.

Keywords

💡Total Productive Maintenance (TPM)

TPM is a comprehensive approach to equipment maintenance that aims to maximize efficiency and effectiveness. It involves everyone in the organization, from the top management to the workers, to ensure that equipment is well-maintained and operates at its best. The video emphasizes TPM as a lean strategy that combines preventive maintenance with total quality control and employee involvement, which is crucial for improving the manufacturing process. It contrasts TPM with a reactive approach that only fixes machines after they break down, highlighting the benefits of a proactive maintenance culture.

💡Preventive Maintenance

Preventive maintenance is a strategy to perform regular checks and services on equipment to prevent failures before they occur. In the context of the video, preventive maintenance is a core component of TPM. It is about scheduling routine maintenance at recommended intervals to ensure machines are kept in optimal condition, which helps to avoid unexpected breakdowns and reduces downtime. The video suggests building a database for each piece of equipment to guide this process.

💡Total Quality Control

Total Quality Control (TQC) is a management approach that aims to improve the quality of products and services through the participation of all members of an organization. In the video, TQC is mentioned as one of the elements combined with preventive maintenance to form TPM. It implies a systematic approach to maintaining high standards of quality in all aspects of production, which is essential for the success of TPM.

💡Total Employee Involvement

Total Employee Involvement (TEI) is a concept where every employee takes part in the improvement of business operations. The video stresses that TPM is not just for maintenance staff; it requires the commitment and involvement of all employees. Each team member is responsible for maintaining a clean and safe work environment, which is a part of the TPM strategy to prevent equipment failure and ensure smooth operations.

💡Downtime

Downtime refers to the period when a machine or system is not operational, typically due to maintenance or failure. The video uses downtime as a measure of the inefficiencies caused by poor maintenance practices. It illustrates how a reactive maintenance approach can lead to significant downtime for even minor repairs, whereas TPM aims to minimize this by preventing breakdowns through proactive measures.

💡Equipment History

Equipment history is the record of an equipment's operational and maintenance data over time. The video suggests that knowing the equipment's history is the first step in TPM. By building a database for each piece of equipment, based on supplier recommendations and operating conditions, teams can better understand what maintenance is needed and when, thus avoiding guesswork and improving efficiency.

💡Standardization

Standardization in the context of TPM refers to the process of setting and validating key parameters and set points for each product. The video explains that once the equipment database is built, the processes must be standardized to ensure consistency in maintenance and operation. This helps in identifying and minimizing losses, which is a critical step towards improving the overall performance of the equipment.

💡Planned Maintenance

Planned maintenance is a systematic approach to servicing equipment at predetermined intervals or under specific conditions. The video mentions planned maintenance as a key practice within TPM, where routine maintenance is scheduled to maintain each part of the machine, improving machine performance and preventing unexpected failures.

💡Cleanliness

Cleanliness is emphasized in TPM as a part of the procedure to maintain equipment. The video points out that keeping equipment clean is not just about aesthetics; it's a practical measure to detect faults at an early stage, thus avoiding sudden breakdowns. Each team member is responsible for ensuring a clean and safe work environment, which is integral to TPM's preventive approach.

💡Spare Parts

Spare parts are备用部件 used to replace worn or broken components in machinery. The video discusses the analysis of spare parts based on consumption and past purchases, ensuring that frequently worn parts are always accessible. This is part of TPM's strategy to reduce downtime by being prepared for quick repairs when needed.

💡Continuous Improvement

Continuous improvement is the ongoing effort to enhance processes, products, or services. The video concludes with the idea that TPM involves a continuous improvement process, where key process indicators are monitored and managed. This approach helps in reducing breakdowns and improving machine speed and quality, ensuring that the business operates efficiently.

Highlights

Businesses face issues with workers neglecting routine maintenance.

Machines that aren't maintained can lead to significant operational issues.

A reactive maintenance approach can result in long downtimes and costly repairs.

Total Productive Maintenance (TPM) is introduced as a solution.

TPM combines preventive maintenance with total quality control and employee involvement.

TPM is an equipment improvement strategy for the entire organization.

TPM aims to eliminate major equipment-related losses.

There are seven pillars to TPM ensuring a practical and sustainable approach.

TPM begins with understanding your equipment's history.

Building a database for each piece of equipment based on supplier recommendations and operating conditions.

Employees are trained to know what to maintain and when.

Standardizing processes by validating key parameters and set points for each product.

Planned maintenance schedules are established to improve machine performance.

Regular cleaning is part of maintaining a clean and safe work environment.

Spare parts analysis ensures frequently used parts are always accessible.

A pit-stop approach is taken to trial standard operating procedures.

Key process indicators are monitored and managed for continuous improvement.

TPM reduces breakdowns, machine speed, and quality problems.

With TPM, there's an efficient system in place where everyone owns their role.

Contact us to find out more about what TPM can do for your business.

Transcripts

say it looks like your business is going

well but let's take a closer look hmm

your workers don't want to be bothered

with routine maintenance and when

machines aren't maintained or when

they're so dirty you can't even read the

gauges well things go wrong and if your

company's approach is to wait until

something breaks do a quick repair and

then go right back into operation

eventually you'll have bigger problems

like long amounts of downtime throughout

the company just to replace one small

part and that's where total productive

maintenance or TPM comes in TPM is the

lean approach to improving the

manufacturing process combining the

traditional practice of preventive

maintenance with total quality control

and total employee involvement TPM is

not just an improvement program for

maintenance staff only or a program to

only cosmetically improve machines it is

an organization-wide equipment

improvement strategy which focuses on

eliminating the major equipment related

losses there are many approaches to TPM

at four principles we've identified

seven pillars to ensure a practical

sustainable approach it all begins with

knowing your equipments history instead

of finding out how your equipment works

only when it fails we help your team

build a database for each piece of

equipment based on supplier

recommendations and the operating

conditions so there's no guesswork your

employees gain the skills and knowledge

to know exactly what to maintain and

when and how long it will take if a part

fails once the database is built the

processes have to be standardized

validating the key parameters and set

points for each product and then

detailed training begins on how to

measure the process identify losses and

put in place solutions that will improve

the process we then begin planned

maintenance where routine maintenance is

scheduled with actions maintaining each

part of the machine at recommended

intervals to improve machine performance

keeping the equipment clean is part of

the procedure

each team member is responsible for a

clean safe work environment regular

cleaning can detect fall

at an early stage avoiding sudden

breakdowns or bigger problems in the

future

spare parts are analyzed based on

consumption and past purchases sell the

spare parts that wear out often are

always accessible and once the system is

set up we take a pit-stop approach to

trial standard operating procedure tasks

we analyze what is and what isn't

working and key process indicators are

monitored and managed to continuously

improve the process so with TPM

breakdowns and machine speed and quality

problems are reduced and when things do

go wrong we don't have wasted time

missing parts and idle workers we have

an efficient system in place where

everyone owns his role in the

implementation these seven pillars along

with a continuous improvement process

will help you achieve total productive

maintenance to find out more contact us

today let us show you what TPM can do

for your business