Even the most versatile and pocket-friendly industries are prone to many vulnerabilities. But TPM, or the Total Productive Maintenance approach with its 8 pillars, can help reduce and fight these breakdowns.
So, read on to find out how TPM can help protect and save industries from machine failures and malfunctioning. The write-up will surely lead your way to apply the eight pillars of TPM to your industry and keep it from any uncertainties!
Introduction to Total Productive Maintenance
The Total Productive Maintenance mechanism or TPM is a system that helps to keep up the equipment’s effectiveness with the idea of everyone getting the entire workforce involved in the process.
This means that when you and your team collectively work towards preventive maintenance and proactive emphasis, it will result in fewer breakdowns and build a safer workplace for all.
However, it can be challenging for companies to understand and implement the TPM mechanism. So, let us take you through the 8 pillars of TPM that will help you learn more about the process and its execution.
The 8 Pillars of TPM
TPM is known for its 5S foundation and the eight-pillar system. The 8 pillars of TPM cover the activities that care for and maintain all the parts of the industry. These include –
Planned Maintenance is one of the essential pillars of TPM. It is also known as preventive Maintenance and is usually done before machine breakdown. Industries plan it according to the factors like machine age, failure rates, etc.
It is considered the best way to avoid downtime and uptime.
Integrity in Quality
Quality Integration is about manufacturing zero defective products that will finally lead to customer satisfaction. Total Productive Management can help quality management and implement the processes linked to enhancing the organization’s quality.
Autonomous Maintenance is another crucial aspect of Total Productive Maintenance. It is when the responsibility of machine maintenance, i.e., its upkeep, cleanliness, inspection, and minute updates, is given to the owner.
Workers get used to the assets and skillfully take care of the machine. It is essential as it helps increase the worker’s skills and reduce capital costs. Timely Maintenance reduces capital expenditure and, hence, cuts expenses.
Management of new equipment
A well-suited TPM strategy always includes the management and upkeep of new equipment as one of the 8 pillars of TPM. Here, the productivity and reliability of the machines are guaranteed from the very first day. It is effective management from the early stage that will help in better designing, which in turn leads to easy operation and Maintenance.
However, the process should consider the following factors –
- Easy operation, lubrication, and inspection
- Easy Clamping and Quick Adjustments
- Enhanced safety features
- Effective Feedback mechanism
The mentioned will help in more effective and efficient early equipment management.
Administrative Management or Office TPM is about designing functions that help in the application and understanding of the principles of lean manufacturing. It eases the value-adding process and works towards providing effective services.
Safety, health, and environment
This pillar of Total Productive Maintenance ensures that workers get a safe and healthy environment to work in. It mainly aims at three zeros, i.e.,
- Zero Pollution
- Zero Work Accidents
- Zero Burnouts
The process helps in increasing the productivity and quality of production. It is implemented using machine guards and Standard Operating Procedures (SOP). Using first aid kits and personal protective equipment can enhance the process and improve safety in the work area.
Skill enhancement through training and education
Skill enhancement through training and education is essential to involve all organization members in the development process. It is an investment that will help boost returns and cause a cut in costs. Employees can carry out the essential maintenance activities that earlier required a maintenance team. The Maintenance will now get time and energy to utilize their skills in being more proactive and better problem solvers. Managers can learn to be efficient mentors, and together everyone can work to bring success and brilliance to the company.
Concentrated Improvement or Kaizen, when implemented through the 8 pillars of Total Productive Maintenance, can help improve the organization’s efficiency and productivity.
The process includes forming teams in each department and organizing an event where groups raise the problem/issues faced during the production process. The team works together to get the root cause of the problems and suggest measures to help solve them. These issues are noted, and a baseline is created that will be used as a comparison to future achievements.
Implementation of the 8 pillars of TPM
TPM’s eight-fold strategy is well-organized and systematically designed; however, it can only be effectively implemented if you go for a rational CMMS or Computerized Maintenance Management System. It is because production plants may experience a machine breakdown and waste of many essential resources in the production process. Hence, it is important to share the information stored in these management systems with everyone in the organization and maintain their records.
So, to maintain the system, you need to share the CMMS access with three groups: operators, engineers, and health and safety managers.
Operators, managers, and supervisors work with equipment daily and know the exact differences between smooth functioning and glitches. Similarly, health and safety are important for any industry; thus, having safety managers in the CMMS is another essential aspect. Finally, engineers must curate the data and turn it into a reliable matrix when a lot of information is added to the maintenance system. The maintenance matrix will then help you to implement the TPM mechanism successfully, and you can cut the number of breakdowns and founderings that may occur anytime in the industry.
The write-up clearly defines the role of Total Productive Maintenance in the manufacturing industries. However, the system highly relies on the Computerized Maintenance Management System (CMMS). Hence, one should understand that both systems work hand-in-hand to help procure the best results.
To conclude, the TPM mechanism helps to reduce machine breakdowns, but with some other conditions applied. Nevertheless, you can implement the strategy in any industry and save it from other future uncertainties.