TOTAL PRODUCTION MANAGEMENT

TOTAL PRODUCTION MANAGEMENT

TPM (Total Productive Maintenance) is a systematic approach to eliminate waste associated with production equipment and machinery.  TPM focuses on involving machine operator in the routine checks and cleaning of the machine to detect problems earlier.  Other areas of emphasis include minimizing machine "downtime" resulting from unexpected breakdowns, fully utilizing a machine's capabilities, and tracking life cycle cost.
It is a holistic approach to equipment maintenance that strives to achieve perfect production:
§  No Breakdowns
§  No Small Stops or Slow Running
§  No Defects:
§  No Accidents (Safe working environment)

TPM emphasizes proactive and preventative maintenance to maximize the operational efficiency of equipment. It blurs the distinction between the roles of production and maintenance by placing a strong emphasis on empowering operators to help maintain their equipment.
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, and eliminating defects).

With the adoption of TPM, enterprise can benefit from the following aspects:
v  Involve machine operators in basic daily maintenance tasks
v  Earlier detection of factors critical to maintaining equipment "uptime"
v  Attacks the manufacturing equipment losses of breakdowns, set-ups, adjustments, reduced speed, scrap and rework.  
v  Measure impact of defects, sub-optimal performance, and downtime using OEE (Overall Equipment Effectiveness)
v  Reduce capital expenditure through equipment refurbishment and capacity improvements
 THE TRADITIONAL TPM MODEL
The traditional approach to TPM was developed in the 1960s and consists of 5S as a foundation and eight supporting activities (sometimes referred to as pillars).

5S Foundation

The goal of 5S is to create a work environment that is clean and well-organized. It consists of five elements:
§  Sort (eliminate anything that is not truly needed in the work area)
§  Set in Order (organize the remaining items)
§  Shine (clean and inspect the work area)
§  Standardize (create standards for performing the above three activities)
§  Sustain (ensure the standards are regularly applied)
It should be reasonably intuitive how 5S creates a foundation for well-running equipment. For example, in a clean and well-organized work environment, tools and parts are much easier to find, and it is much easier to spot emerging issues such as fluid leaks, material spills, metal shavings from unexpected wear, hairline cracks in mechanisms, etc.

The Eight Pillars

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

Pillar
What Is It?
Autonomous Maintenance
Places responsibility for routine maintenance, such as cleaning, lubricating, and inspection, in the hands of operators.
Planned Maintenance
Schedules maintenance tasks based on predicted and/or measured failure rates.
Quality Maintenance
Design error detection and prevention into production processes. Apply root cause analysis to eliminate recurring sources of quality defects.
Focused Improvement
Have small groups of employees work together proactively to achieve regular, incremental improvements in equipment operation.
Early Equipment Management
Directs practical knowledge and understanding of manufacturing equipment gained through TPM towards improving the design of new equipment.
Training and Education
Fill in knowledge gaps necessary to achieve TPM goals. Applies to operators, maintenance personnel and managers.
Safety, Health, Environment
Maintain a safe and healthy working environment.
TPM in Administration
Apply TPM techniques to administrative functions.


In Summary, the implementation of TPM can lead to significant manufacturing cost reductions, improvement in production efficiency and allow manufacturing organizations better placed to survive in increasingly competitive global markets.