1. Focused Improvements (Kaizen)

Kaizen is a continuous improvement process that helps organizations to improve quality and productivity by identifying, analyzing, and eliminating Non-Value Adding activities.

Teams are formed with people in various departments/functions of the company. The problems/issues related to the equipment are identified and improvement goals are set in the kaizen event.

During the events, the participants map the current state as a baseline performance measure on which they will compare any future performance after improvement. The team works together and come up with the analysis of the root cause of the problems and implement solutions and ensure that they are sustained.

2. Autonomous Maintenance

Autonomous Maintenance activity is done by the operators and it creates ownership with the machine. The operator of the machine is responsible for daily cleaning and minor maintenance activities.

Skill levels of workers increase as they understand the general working of equipment thus achieving the multi-skilling objective of a lean organization

Capital investments reduce because the organization has reliable equipment. The lifespan of machines increase as deterioration of machine is checked through constant monitoring and maintenance.

3. Planned Maintenance

Planned maintenance / Preventive Maintenance happens before the machine breaks down. This is planned considering various factors like the machine failure rate, age of the machine, etc.

Production functions should build up some inventory to allow for the planned maintenance to be carried out as they have prior information of when these activities are scheduled.

4. Early Equipment Maintenance (EEM)

Early equipment maintenance is to build in high efficiency from the design stage. EEM will help to design equipment in a way that it is easy to operate and maintain and is delivered to the site in a condition that is equal to autonomous maintenance standards.

The productivity as well as output quality of the machines also guaranteed from the very first day when the equipment is commissioned.

Below are factors to be considered in EEM

• Ease of cleaning, lubrication, and inspection
• Accessibility of equipment parts
• Make the machines easier to operate (ergonomic aspects)
• Making it easier for the change-over (Easy clamping, Quick adjustment settings, etc)
• Feedback mechanisms to alert defective products (Visual Indicators)
• Increased safety features

5. Quality Maintenance

This TPM pillar address improves quality by ensuring equipment is able to detect and prevent errors during production. By detecting errors during production, processes become reliable to produce the right components in the first time and this reduces the Cost of Poor Quality (COPQ).

Using lean tools such as autonomation (jidoka) and on lights, machines detect and report any abnormal conditions, thereby releasing the operators from tedious monitoring.

6. Training and Education

TPM Education and Training pillar is a companywide initiative that involves all levels in the organization from the operators to senior managers

Through training, operators’ skills levels are raised to the point where they are able to carry out basic maintenance activities that were previously done by the maintenance team.

The maintenance team members are taught higher-level skills such as preventive maintenance and analytical skills to help them become more proactive in problem-solving.

Managers also learn the TPM skills so as to become competent mentors to their juniors as well as be involved in coaching programs.

7. Safety, Health & Environment

The Health, Safety, and Environment pillar of Total Productive Maintenance ensures that all workers are provided with an environment that is safe and the unsafe conditions are eliminated.

In a safe environment, employees’ attitudes towards work changes dramatically resulting in productivity, Quality and Delivery Performance improvements.

The teams will work towards making machines safe to use for the operators by putting in place machine guards, Standard Operating Procedures (SOP), use of personal protective equipment, and first-aid kits in the work area. Each of these measures is aimed at improving the safety of the machines so as to have a more productive workforce.

8. Office TPM

Make all supportive functions to understand and apply the principles of lean in their own operations. This makes it easy for them to provide efficient service to the Value Adding processes.

The TPM principles can also be applied as stand-alone techniques to improve the efficiency of these supportive functions. For example, if the administrative functions are able to improve their order processing procedures, then the materials will get to the shop-floor in a flawless manner which will have a positive effect on the workflow.

These are the eight pillars of TPM.

To learn more about the TPM and its Pillars in detail or to get our assistance in implementing TPM in your organization, contact us by clicking here