Total Productive Maintenance/Management

Total Productive Maintenance/Management

Total Productive Maintenance (TPM) which is one of the key concepts of Lean Manufacturing, challenges the view that maintenance is no more than a function that operates in the background and only appears when needed. The primary goals of TPM are zero breakdowns and zero defects. When breakdowns and defects are eliminated, equipment operation rates improve, costs are reduced, inventory can be minimized, and as a consequence, labor productivity increases. One firm reduced the number of breakdowns to 1/50 of the original number. Some companies show 17-26 percent increases in equipment operation rates while others show a 90 percent reduction in process defects. Labor productivity generally increased by 40-50 percent. Of course, such results cannot be achieved overnight. Typically, it takes an average of three years from the introduction of TPM to achieve prize-winning results. Furthermore, in the early stages of TPM, the company must bear the additional expense of restoring equipment to its proper condition and educating personnel about the equipment. The actual cost depends on the quality of the equipment and the quality of maintenance. As productivity increases, however, these costs are quickly replaced by profits.

Four Developmental Stages of TPM

  • Stage 1:Breakdown Maintenance
  • Stage 2: Preventive Maintenance
  • Stage 3: Productive Maintenance
  • Stage 4: TPM

Until the 1970’s Japan’s PM consisted mainly of preventive maintenance, or time-based maintenance featuring periodic servicing and overhaul. During the 1980’s preventive maintenance is rapidly being replaced by predictive maintenance, or condition-based maintenance. Preventive maintenance uses modern monitoring and analyzing techniques to diagnose the condition of equipment during operation to identify the signs of deterioration or imminent failure.

Tangible Benefits from TPM

  • Reduction of Manufacturing Cost by 20 – 30 %
  • Improve the Net productivity up by 30 - 60 %
    • Number of Breakdown reduced by 10 - 80%
    • Overall Plant Effectiveness by 30 - 50 %
  • Reduction Defective Products by 50%
    • Customer Complain down by 40 - 60%
  • Inventory (Only Spare parts) down by 30%
  • Major Accidents reduced by 50%
  • Minor Accidents reduced by 40%
  • Enhance the Employees Moral by 5 times
    • Improvement of Suggestion 10 times minimum.
    • Workforce uncertain absent-ism down by 5 times.

In-tangible Benefits from TPM

  • Achieving full Self Management – Operators have ownership on their equipment
  • Enhancing skill and knowledge of workforce by training.
  • Building CAN DO attitude by eliminating breakdowns and defects
  • Enhancing the communication among all team members.
  • Make the workplace clean, bright and lively.
  • Giving plant visitors a better image.
  • Making all losses more visible.
  • Enhance safety of plant
  • Making the plant with more visual display.

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