- 1 WHAT IS TPM?
- 2 THE 8 PILLARS OF THE TPM
- 2.1 Focused Improvements (Kobetsu Kaizen meaning)
- 2.2 Autonomous Maintenance (Jishu Hozen meaning)
- 2.3 Planned maintenance
- 2.4 Quality in maintenance (Hinshitsu Hozen meaning)
- 2.5 Maintenance prevention
- 2.6 Activities of administrative and support departments
- 2.7 Training and Education
- 2.8 Security and Environment Management
WHAT IS TPM?
TPM is a maintenance philosophy whose objective is to eliminate production losses due to the condition of the equipment; that is, to keep the equipment in a position to produce at its maximum capacity products of the expected quality; without unscheduled stops. This means:
- Zero breakdowns
- Zero downtime
- No loss of performance or productive capacity due to these of the equipment
- Zero defects due to poor condition of the equipment
The name is then perfectly understood: total productive maintenance, or maintenance that provides maximum or total productivity.
THE 8 PILLARS OF THE TPM
The pillars of the TPM are 8 and they are the fundamental strategies to develop this methodology. These pillars support the construction of an orderly production system. They are implemented following a disciplined, powerful and effective methodology.
The 8 TPM pillars are:
- Focused Improvement (Kobetsu Kaizen)
- Autonomous Maintenance (Jishu Hozen)
- Planned maintenance
- Quality in Maintenance (Hinshitsu Hozen)
- Maintenance prevention
- Activities of administrative and support departments
- Training and Education
- Security and Environment Management
Focused Improvements (Kobetsu Kaizen meaning)
These are activities that are developed with the intervention of the different areas involved in the production process, in order to maximize the overall effectiveness of equipment, processes and plants.
Autonomous Maintenance (Jishu Hozen meaning)
One of the activities of the TPM system is the participation of production personnel in maintenance activities.
The autonomous maintenance is based on the knowledge that the operator has to control the conditions of the equipment; such as, mechanisms, operative aspects, care and conservation, handling, breakdowns, etc.
With this knowledge the operators will be able to understand the importance of the conservation of the working conditions, the need to carry out preventive inspections, to participate in the analysis of problems and the accomplishment of light maintenance works in a first stage; to later assimilate more complex maintenance actions.
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The objective of planned maintenance is to eliminate the problems of the equipment through improvement, prevention and prediction actions. It is necessary to have a good data collection and an excellent analysis.
Quality in maintenance (Hinshitsu Hozen meaning)
The purpose of this maintenance is to improve the quality of the product by reducing variability; by controlling the conditions of the components and conditions of the equipment that have direct impact on the quality characteristics of the product.
Improvement activities are carried out during the design, construction and tuning phase of the equipment, in order to reduce maintenance costs during operation.
A company that intends to acquire new equipment can make use of the history of the performance of the machinery it owns, in order to identify possible improvements in the design and drastically reduce the causes of breakdowns from the very moment a new piece of equipment is negotiated.
Activities of administrative and support departments
These activities do not involve the production team. Planning, development and administration departments do not produce a direct value as production; but they offer the necessary support so that the productive process works efficiently, with the lowest costs, requested opportunity and with the highest quality.
Their support is usually offered through a process that produces information. There too, the potential losses to be recovered are enormous.
Training and Education
The training must be multipurpose, according to what the plant and the organization needs, because many of the wastes are due to the fact that people are not well trained.
Therefore the planning of the training of people must go out of the opportunities found in the performance of the employees and operators.
Security and Environment Management
The number of accidents grows in proportion to the number of small stops. For this reason the development of autonomous maintenance and an effective implementation of 5S are the basis of safety.
Training in perception skills is the basis of risk identification as deeply trained personnel in the team assume greater responsibility for their health and safety.