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Objective zero failure with the TPM method, Total Productive Maintenance
Do you want to reduce time and wasted resources? Produce more efficiently and reduce waste at a lower cost?
Choose the TPM method, Total Productive Maintenance, which improves the productivity of your equipment by reducing downtime and breakdowns. While optimising productivity, quality and other performance indicators. It's one of the steps of Lean Manufacturing.
Definition of the maintenance's technique : the TPM
The TPM method, Total Productive Maintenance, is a practice aimed at building a corporate culture that improves the efficiency of the production system. It allows the gradual transition from a curative maintenance system to preventive maintenance (or even predictive maintenance in some cases).
This is the result of a managerial focus on :
- Establishing a Continuous Improvement Policy
- Involving all staff by empowering them
- Improving performance QUALITY / COSTS / DEADLINES
- Improving equipment (productivity, efficiencies, etc.).
TOTAL
Considering all aspects of maintenance, involve everyone in it
PRODUCTIVE
Ensuring maintenance by producing and penalising production as little as possible
MAINTENANCE
Maintainenance: repair, clean and grease. Spending the necessary time on this.
History of TPM, Total Productive Maintenance
TPM succeeded the American Preventive Maintenance (PM) and was developed in Japan after the Second World War. TPM was introduced in the factories of the Nippondenso group before being formalised by the JIPM, Japan Institute of Plant Management. In 1989, the JIPM defined 8 pillars on which a TPM approach is based to achieve a high level of industrial performance. TPM is a registered trademark of JIPM. What has changed in relation to PM is the participatory approach, the active participation of operators who know their machine(s) and therefore contribute effectively to its maintenance.
TPM GOALS
Purpose of the TPM approach, Total Productive Maintenance
The TPM approach, Total Productive Maintenance, focuses on the machine. It is increasingly becoming the first step in launching performance improvement initiatives.
To do this, the company must have eliminated the unexpected and chance in its production activities.
To be efficient, a site needs a reliable and available production tool.
La TPM, Total Productive Maintenance permet de visualiser facilement et sous forme graphique (Pareto, courbes, etc…) les principaux indicateurs et les facteurs qui influent sur leurs résultats. Ces graphiques fournissent des rapports, établis à partir de critères TPM, délivrant ainsi des analyses personnalisées pour des projections sur des durées ou des ressources particulières.
Le but de l’analyse des données est de déterminer les causes principales de sous-performance et d’orienter les actions de progrès sur les causes générant les gains de TRS, Taux de Rendement Synthétique, les plus importants.
Les systèmes TPM ont trois objectifs majeurs :
Minimiser la sous-utilisation de l’équipement causant de nombreuses pertes, y compris financières.
Participer à la conservation des équipements par un vrai suivi de la maintenance
Améliorer l’organisation et agir sur les facteurs qui permettent d’obtenir les meilleurs rendements.
Advantages in terms of direct results
- Establishment of maintenance and cleanliness on workstations and their environment
- Setting up a visual organisation
- Eliminating waste of time and material
- Improvement of equipment monitoring
- General improvement of the environment
Behaviour benefits
- Communicate and involve everyone
- Reconsider your habits
- Maintaining
- Making sustainable the results achieved and progressing continuously
- Respecting commitments and collective rules
Maintenance station with TPM
The maintenance station is associated with each machine or manufacturing cell requiring immediate availability of tools for:
- Meet preventive maintenance requirements
- Reduction of space requirements
- Optimisation of the working space and creation of a clean, tidy and rational space
TPM cleaning station
Ces postes de propreté offrent une solution complète au sein de l’entreprise, des services, des bureaux tels que :
- An increase in organisation and quality of work
- An increase in productivity and efficiency
- Accidents and technical breakdowns or malfunctions reduction
TPM visual communication support
La gestion des anomalies par les tableaux de communication est approuvée avec les plus grands groupes industriels permettent aux opérateurs de :
- Express yourself in real time and without constraint
- Implementation is fast, efficient, simple and economical
- To encourage better overall performance
SUCCEED IN ITS TPM METHOD
The TPM (Total Productive Maintenance) approach improves the production capacity of technical resources by building a system that avoids losses and waste such as "zero accidents, zero faults and zero breakdowns". This technique is based on fieldwork (Gemba) and concret (Genbutsu) throughout the life cycle of the production system.
The TPM involves the participation of all divisions. Not only those related to production but also the conception of production, development, marketing and administrative services, at all hierarchical levels, from managers to operators.
It enables to reach the "zero losses" by engaging in small group improvement initiatives. Everyone must find an advantage in the TPM approach and this is not always the financial aspect even if it is put forward. This argument sometimes masks deeper needs. One of the indeniable advantages for operators is that "it feels good to remove the thorn in your side".
This thorn can be as well the routine that one perceives, the attitude of the hierarchy, the feeling of not being heard as the difficulties that one encounters to carry out its work in normal conditions (difficulties due to the material, the raw materials, the organisation, ergonomy issues...). This thorn can also be the need to feel useful, to be able to solve the problems encountered.
PLAY-BASED TRAINING FOR THE TPM METHOD
Fun e-learning game for professionals
Average duration: 2h30
On the principle of an automobile route journey presented in the form of the game of the Goose sown with hazards, one tries to eliminate all sources of dysfunction of the means of production (external and internal).
Don't wait any longer to train your colleagues in TPM through games
The TPM-PDCA-SUGGESTION Starter Kit: Simple development of a PDCA board, improvement proposals (suggestion) and TPM (Total Productive Maintenance) as part of a pilot project following the game.
Results: collective and effective success.
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