TPM is about maximising the overall effectiveness of equipment through the people who operate and maintain that equipment. In order to provide the essential link between equipment and people it is essential to identify a clear set of phases and steps which together make up the TPM improvement plan.
There are three phases of the TPM Implementation Plan:
The measurement cycle, which assesses the present effectiveness of the equipment and provides a baseline for the measurement of future improvement. Only after understanding the current situation of Asset efficiency, right action plan can be generated. Many organisations may not have good data collection system before starting TPM Implementation. This current OEE level must be estimated based on designed capacity vs actual good output every month. After understanding the current approximate level of OEE, a data collection system must be established to measure OEE on a daily basis. Excel templates can be used to calculate OEE initially and investment in any OEE software must be done only after OEE is fully understood by the shop floor staff and data collection on excel based systems has been stabilised.
Measurement of 6 big OEE losses is very important before TPM implementation can be started. Only after assessment of the losses, right TPM pillars can be chosen for starting TPM implementation
The condition cycle, which establishes the present condition of the equipment and identifies the areas for improvement and future asset care. This cycle covers assessing the current situation of equipments through observations and audits. Each and every component of the equipment is assessed against various parameters to understand the current condition. Next step in condition cycle is to start planning for improvements in equipment based on assessed situation. if planning is done well, lot of time can be saved during repairs and problem correction work
The problem prevention cycle, which moves equipment effectiveness forward along the road to world-class performance. this is most important cycle of TPM implementation and covers establishing a root cause analysis system to continuously work on identification, correction and prevention of all the causes resulting in loss of equipment efficiency