Kaizen Management Practices

Kaizen Management Practices

Total Productive
Maintenance

Total Productive Maintenance

To remain competitive in the ever changing manufacturing landscape, efficiency and reliability are essential. The goal of Total Productive Maintenance (TPM) is to improve operational effectiveness and productivity through a holistic approach to maintenance. Implementing and optimizing TPM techniques is made possible in large part by TPM consultancy, a specialized profession within management and engineering.

Meaning of TPM ( Total Productive Maintenance)

A system for maintaining machinery to prevent malfunctions, downtime, machine stoppages, incidents, and accidents is called total productive maintenance. It can be used as a tool inside the Lean manufacturing consulting in Delhi.  All employees must participate in TPM, including managers, engineers, quality inspectors, and maintenance personnel. Its main objective is to minimize significant machine losses, which impair machinery in terms of scrap, rework, minor stops, downtime, and speed losses. It looks at the equipment’s entire life cycle to update maintenance procedures, initiatives, and advancements based on the stage of the equipment’s life cycle.

Pillars of TPM

The classic approach to Total Productive Maintenance, which was formed in the 1960s and consists of eight supporting activities, is based on the five S’s.Eight supporting pillars plus the 5S foundation (Sort, Set in Order, Shine, Standardize, and Sustain) make up the traditional TPM model.

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5S Foundation

Establishing a tidy and well-organized workplace is the aim of 5S. It is made up of five components.

  • Sort – Remove anything from the workspace that is not required.
  • Straighten – Arrange the rest of the items.
  • Shine – Examine and clear the workspace.
  • Standardize – Establish guidelines for carrying out the above mentioned three tasks.
  • Sustain – Make sure the guidelines are followed on a continuous basis.

Eight TPM Pillars

Proactive and protective methods for improving equipment’s reliability are the main focus of the eight TPM pillars.

  • Autonomous Maintenance – Operators receive training on performing basic routine maintenance (such as cleaning, inspecting, and polishing machines). Eventually, this frees up the maintenance personnel to work on more complicated problems alone. Employees will gain ownership as well as enhanced skills, knowledge, and competency as a result.
  • Planned Maintenance – Instead of being reactive, the maintenance tasks must be proactive. It is not ideal to do normal maintenance and only service equipment when it breaks down; as a result, corrective action will be taken rather than preventive measures.
  • Quality Maintenance – In TPM, defect identification and prevention are essential to removing quality concerns. The focus should be on the production process elements that are essential to quality, and a comprehensive assessment of the fundamental causes should be conducted.
  • Focused Improvement – Focused improvement is a key component of lean. System analysis and the discovery of wasteful and non-value-adding operations can be used to address goal-setting, development evaluation, and problem-solving.
  • Early Equipment Management – Improved thinking about equipment maintenance through TPM can result from applying knowledge to equipment design, or early equipment management (EEM). This benefits the maintenance program as a whole and considers the need for extra safety precautions and a simpler switchover.

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  • Training and Education – A robust training program is necessary for the TPM to be implemented successfully. Each and every employee must understand TPM and its importance. Employees should be trained in problem-solving techniques and preventative maintenance. The maintenance team must receive intensive training in preventive maintenance.
  • Safety Health and Environment – The focus on minimizing risks and ensuring employee safety. It is essential to make sure that health and safety are to be considered while designing new machinery and related maintenance policies. To achieve the objective of zero occurrences, protocols, risk assessments, and hazard analysis should be employed.
  • TPM in administration – TPM should have the backing of the organization’s administrative team. Office TPM seeks to reduce wasted spending on things like idle, breakdown, and long setup times while also boosting productivity.

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Dr.Ashok Puri Visual Management an Lean Expert

Dr. Ashok Puri - Total Productive Maintenance Expert

Dr.Ashok Puri is a well-known management expert. He is a philosopher, author, engineer, and academic who has made significant contributions to the fields of Kaizen, Lean Manufacturing, and Organization Excellence. He encourages his clients and students to review and reevaluate their business methods with a fresh approach. He has created Micro Management Models for improved Organizational Governance for Indian SME’s. You can also visit his website www.kaizenguru.in for better understanding and implementing Total Productive Maintenance in your organization.