Total Productive Maintenance
Consultancy
What is Total Productive Maintenance (TPM)?
It is a maintenance program that incorporates a newly defined concept for the upkeep of facilities and equipment.
The Purpose of the TPM Program
The goal is to significantly increase production while simultaneously improving employee morale and job satisfaction.
TPM places maintenance at the center of attention, recognizing it as a necessary and vital part of the business.
It is no longer seen as a non-profit activity.
Maintenance downtime is scheduled as part of the production day and, in some cases, an integral part of the production process.
The aim is to minimize emergency and unplanned maintenance.
Why TPM?
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TPM was developed to achieve the following goals:
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Preventing waste in a rapidly changing economic environment.
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Producing products without compromising product quality.
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Reducing costs.
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Producing in the shortest possible time with low batch quantities.
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Ensuring that products shipped to customers are defect-free.
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TPM Goals
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Achieve a minimum of 90% OEE (Overall Equipment Effectiveness).
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Keep machines running even during lunch breaks. (Lunch breaks are for operators, not machines!)
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Operate in a way that eliminates customer complaints.
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Reduce production costs by 30%.
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Achieve a 100% success rate in delivering goods as requested by the customer.
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Provide an accident-free environment.
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Triple employee/worker suggestions. Develop a versatile and flexible approach.
Reasons for TPM
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Adopting a lifecycle approach for overall improvement of production equipment performance.
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Increasing the productivity of highly motivated employees achieved through business growth.
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Utilizing voluntary small group activities to identify the causes of failures and make possible plant and equipment changes.
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The Uniqueness of TPM
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The biggest difference between TPM and other concepts is that operators are also involved in the maintenance process.
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The "I (Production operators) do the work, you (Maintenance department) fix it" concept is not applied.
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TPM Goals
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Achieve Zero Defects, Zero Failures, and Zero Accidents in all operations.
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Involve people at every level of the organization.
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Create different teams to reduce failures and perform self-maintenance.
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Direct Benefits of TPM
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Increased productivity and OEE (Overall Equipment Efficiency)
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Reduced customer complaints.
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30% reduction in production costs.
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Meeting customer needs 100% (Delivering at the right time, in the right quantity, and with the desired quality.)
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Reduced accidents.
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Indirect Benefits of TPM
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Higher level of trust among employees.
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A clean, organized, and attractive work environment.
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Positive change in operator attitudes.
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Achieving goals through teamwork.
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Horizontal dissemination of a new concept across all areas of the organization.
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Sharing knowledge and experience.
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Workers experience a sense of ownership over the machine.
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Challenges Encountered in TPM Implementation
One of the challenges of implementing TPM as a methodology is that it takes many years.
This timeframe depends on the size of the organization.
There is no quick fix for implementing TPM.
This contradicts traditional management improvement strategies.
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Other challenges encountered in implementing TPM include:
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People often show strong resistance to change.
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Many people view TPM only as a "Program of the Month," without focusing on it, and doubt its effectiveness.
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Lack of sufficient resources (people, money, time, etc.) and support.
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Middle managers' insufficient understanding of the methodology and philosophy.
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TPM is not a "quick fix" approach; it requires a cultural shift in our ways of doing business.
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Departmental barriers within the business unit.
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Many people have viewed TPM activities as additional work/threats.