Total Productive Maintenance Programs in Industrial Manufacturing

Published on: January 25, 2019

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Total Productive Maintenance is a support program for performing proactive maintenance with the goal of increasing equipment availability and avoiding breakdowns. TPM programs enable manufacturing units to search for evolutionary changes occurred in the business environment and is an advancing procedure which is followed by most organizations. Total Productive Maintenance is a far-reaching manufacturing enhancement program concentrated on upgrading yield quality with a definitive objective of achieving industrial production with zero deformities.

To expand the chances of accomplishment, the TPM project team should rapidly exhibit both the backbone of their drive and the value of their efforts. For example, improving the throughput of machined parts through a mill not just exhibits the value of the TPM effort, yet in addition decreases personal resistance to future improvements.

Benefits of TPM

A guideline metric for measuring TPM benefits is overall equipment effectiveness or OEE, a composite measure considering gear accessibility, machine execution or run rates, and output quality. A related objective is guaranteeing a sound and safe workplace.

Challenges in TPM in Industrial Manufacturing

The following are five basic early challenges each assembling industry should concentrate on when starting a TPM execution. These challenges are not consecutive but instead will overlap.

Securing top administration support and allocating satisfactory resources to the project

Without top management support, it is difficult for the TPM project team to make significant headway. The entire organization will understand what is important to top management and will respond accordingly. If people do not believe the project efforts are a priority, then those efforts will not be important to the individuals at the supervisory levels or on the manufacturing line.

Furthermore, if top management fully supports the implementation, then sufficient resources will be assigned to the project. These resources should include some of the best people in the organization and should be attached to the project team on a full-time basis.

Building up an extensive project plan

A comprehensive project plan ought to be developed and exhibited to the organization. The program should illustrate schedules, resource requirements, and anticipated advantages. Introduction of the venture assignments, work steps, and other arrangement materials should result in purchase in from all level of the organization.

Work can start as soon as possible and should concentrate on achieving a generally quick ‘win’ that can be demonstrated as immediate progress. Select an area offering brilliant opportunities for quick, positive effect, where personnel support is high, and is sensible in size.

Building up a lean culture over the organization

Before starting an industrial manufacturing TPM  program, the organization should embrace the culture of lean enhancement. Training, preparation, development of cross-functional teams, and application of lean principles ought to be in place. Workers should be occupied with a constant procedure of applying lean methods to eliminate waste, increase quality, and maintain safety in the workplace.

Giving TPM training to all personal

Training should take place before in the project’s lifecycle. All workers must be presented to both the TPM procedure as well as basic lean systems. As a part of securing commitment to the project, all top management staff should also undergo TPM training and, as a result, understand the program’s advantages and requirements.

Implementing CMMS to support projects

Using Computerized maintenance management system, or CMMS, planned maintenance can assist in keeping downtimes at a minimum through both schedule support and decreases in emergency breakdowns. The undertaking group should follow upgrades by means of measurements, for example, OEE.

Overall TPM implementation is crucial for any business requiring machine maintenance. Not only can you reduce overall costs but more importantly time, which we all know is crucial in running an efficient business. If you haven’t already, give serious thought to implementing such a system to improve productivity of your business.

McBride, D. (2010, February 18). How to implement Total Productive Maintenance. Retrieved from https://www.reliableplant.com/Read/8481/total-productive-maintenance
Thompson, P. (2017, November 17).  4 benefits of Total Productive Maintenance in production. Retrieved from https://www.sageautomation.com/blog/4-benefits-of-total-productive-maintenance-in-production
TPM (Total Productive Maintenance). (n.d.). Retrieved from https://www.leanproduction.com/tpm.html

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