Ever heard a captain saying: “Todays airplane machine availability is at 90 %. Welcome on board”? How can airplanes achieve a machine availability of 100 % but production struggles with machine breakdowns and line stoppages? Total Productive Maintenance/TPM will do the trick.
Total Productive Maintenance (TPM)
TPM – What is it?
TPM or Total Productive Maintenance is a philosophy and approach to prevent any machine and equipment downtime at all. But how can that happen?
As all machines have to be cleaned at a certain point in time, Total Productive Maintenance is closely linked to that activity. Cleaning means checking. By doing this, faulty cables, screws or any other component can be detected before they break.
Each operator is responsible for his station or area. Critical components and corners, cables and sensors have to be listed on a regular cleaning check list. The duration (i. e. 5 min) as well as the regularity (i. e. end of each shift) have to be set before. Starting with TPM is that simple.
Take the example of a dirty car. As long as the equipment is dirty nobody will see if there are any faults. By cleaning and touching the car your eyes are stuck on the surface of the car. Scratches can be detected right off the bat.
Same applies to loose cables or sensors. By touching the cable for cleaning you will directly recognize if the cable is about to break. Maintenance can be called far before the machine breaks and worse happens.
How to implement Total Productive Maintenance (TPM)?
Total Productive Maintenance can be implemented in any 5S or cleaning activity. Beside that, TPM workshops can be performed in which a team of 3-10 participants participate. Once a production area for the activity is defined proceed as follows.
First split the assembly line into several areas, each area belongs to one operator. Then clean each area carefully and mark all critical hot spots you detect. Define regular cleaning activities for operators including the detected hot spots for each area (the Total Productive Maintenance cleaning schedule). Implement a Total Productive Maintenance board on which operators can note all faults they will detect during the cleaning activity. Make sure the maintenance department is informed to check the board regularly (i. e. 1x per day). Make sure to discuss all detected faults regularly (i. e. each morning with all responsible persons)
Total Productive Maintenance – Further Readings:
Shingijutsu-based summary – http://www.makigami.info/tpm-maintenance-integration-production/