TPM - Total Productive Maintenance - Management of maintenance of the equipment

Functionality and use

The purpose of TPM — to provide optimal conditions of operation and use of the equipment. Approach of TPM is an element of the concept lean manufacturing — "lean production". Actually, it is about a system, providing to the optimalena a combination of effective use of production capacities and expenses on their maintenance in good repair due to reduction of breakdowns and idle times (including on readjustment) and also performance improvement and improvement of the equipment. Emphasis in this system is placed on prevention and early determination of defects of the equipment which can lead to more serious problems, i.e. TRM assumes active participation in process of improvement of use of an operating equipment of all services of the enterprise. Operators and repairmen whose task is improvement of quality of the equipment take part in TRM. Scheduling of preventive maintenance and the general check is considered the base of TRM. Use of TRM gives the chance to reduce defects in procurements and finished goods at 3-10 times.

System deployment of TRM gives an opportunity to achieve cardinal improvement on the following groups of indicators:

• Reduce cost value by 30%;
• Reduce the number of defects and claims by 10 times;
• Prevent occupational injuries which result can be an absence from work, and exceeding of the adopted standards of impact on the environment;
• Increase labor productivity on added value by 1.5-2 times, in as much time to increase employment of the equipment and reduce the number of breakdowns and accidents in hundreds of times;
• Whenever possible completely to exclude cases of violation of delivery time and to reduce the volume of unfinished production to 50%;
• Increase several times initiative of personnel which is measured by the number of the improvement suggestions submitted by employees.

Directions of deployment of TPM

As a rule, TRM is unrolled in eight directions, the first four from which are directly connected with a manufacturing sector, and the second four concern non-productive divisions of the enterprise.

• The first is conversion of the equipment, implementation of separate improvements which are directed to quality improvement of its service.
• The second direction, is "a gold rod", i.e. the basic in a TRM-system is the organization of independent hardware maintenance by operators. Its sense consists in transition to the operating hardware maintenance personally by the operator.
• The third direction - formation of planned inspection of the equipment, using forces of service of the chief mechanical engineer. Its essence is in that by the best method, combining different types of service to create conditions for the most effective operation of the equipment at minimum flows.
• The fourth the directions - a guarantee of stable growth of qualification and skill of workers without which the purposes of TRM just will not be implemented. In this case categorically it is impossible to rely on a thought that the automated equipment itself makes products, and the master only monitors his work and provides intake of materials, i.e. performs simple transactions which do not require special preparation.
• The fifth - development of the system of control of the equipment at an initial stage of its work and the system of formation of new products. It gives the chance to integrate processes of creation of a lung in production of a product and the equipment easy in use that much more reduces time of emergence of new production lines and terms of an entry of new products into the market.
• The sixth direction - formation of a system of service which is directed to product quality maintenance is based on production of the equipment and maintenance of conditions of its operation under which the release of defective products is excluded.
• The seventh direction – increase in quality of functioning of design, commercial and other non-productive divisions and also the help to production divisions in increase in effectiveness of their work.
• The eighth – formation of the system supporting the favorable environment and safe working conditions.

Deployment of this or that direction depends on the enterprise which starts introduction of the TRM systems, i.e. it independently defines what directions and how it will unroll. However, according to specialists, the synergy effect and reduction of terms of deployment of all system can be reached on condition of the synchronized movement on all selected directions. Perform such method impracticablly. Today the TRM system was widely adopted around the world, practically acquiring the status of the international standard. However there are practically no Russian enterprises which started its mastering.

See Also

MRO

OEE

Links

(TPM) of Total Productive Maintenance. General care of the equipment, key solutions

Implementation of lean production

Dictionary by the logistician