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Total Productive Maintenance Deployment

Total Productive Maintenance (TPM) is a culture that focuses on improving the effectiveness of the plant, equipment and processes through the empowerment of people to achieve Zero BAD (Breakdown, Accident, Defect)

Implementation of TPM would increase financially both the top and the bottom line of any organization. One of the key point of TPM implementation is to reduce 16 types of losses.

Some of the major losses are Breakdown, Setup and adjustment loss, Start-up loss, Minor stoppage and idling loss, Speed loss, Energy loss, Yield loss.

We can achieve top and bottom profit after implementing the TPM Approach. 

TPM(Total Productive Management ) is a holistic approach to equipment maintenance that strives to achieve perfect production. The implementation of a TPM Program creates a shared responsibility for equipment that encourage greater involvement by plant floor workers. In the right environment this can be every effective in improving product (increasing up time, reducing cycle times , and eliminating defects.)

Through the implementation of TPM, we can achieve improvement in PQCSDME (Productivity, Quality , Cost, Safety , Delivery, Morale and Environment)

11 Steps of TPM Implementation

  1. Management’s announcement of intent to introduce TPM into the organization
  2. Assign TPM promotion responsibility and launch an education campaign to introduce TPM to all levels
  3. Establish basic policies and goals of TPM
  4. Formulate a master TPM implementation plan for organization
  5. Kickoff  TPM master plan activities
  6. Set one production cell as Manager Model Cell
  7. Setup and implement Autonomous Maintenance
  8. Establish planned maintenance system
  9. Train Operator and Workman to improve skills
  10. Institute improved equipment maintenance techniques
  11. Realize the benefits!!!    
TOTAL PRODUCTIVE MAINTENANCE

TPM is the foundation for Lean Manufacturing,JIIT, and POKA YOKE.

There are 8 pillars of TPM.In the base, 5-S and Total Employee Involvement is mandatory for effective implementation of TPM. Then implementation of one by one pillar should start. In, TPM, we need tpo focus to make all the machines/ equipments efficient and effective .

Road map TPM Project Deployment

  1. Management’s announcement of intent to introduce TPM into the organization(Plant TPM Committee)
  2. Assign TPM promotion responsibility and launch an education campaign to introduce TPM to all levels
  3. Establish basic policies and goals of TPM.
  4. Formulate a master of TPM implementation plan for organization
  5. Kickoff TPM master plan activities
  6. Set one production cell as Model Cell
  7. Setup and implement Autonomous Maintenance
  8. Establish planned maintenance system
  9. Train Operator and Workman to improve skills
  10. Institute improved equipment maintenance techniques.
  11. Realize the benefit!!