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Total Productive Maintenance (TPM)

TPM originated in Japan in 1971 as a method for improved machine availability through better utilization of maintenance and production resources. TPM is one of the key concepts of Lean Manufacturing and challenges the view that maintenance is no more than a function that operates in the background and only appears when needed. The objective of TPM is to engender a sense of joint responsibility between supervision, operators and engineers, not simply to keep machines running smoothly, but also to extend and optimise their performance overall

TPM is a well proven system that seeks to eliminate breakdowns. As one of the UK’s leading authorities on putting TPM into practice, we combine years of manufacturing experience, unrivalled TPM knowledge and a culture based entirely on results, to ensure you get the best possible working solution

TPMTPM delivers the following benefits:

  • Maximum equipment efficiency
  • Improved machine reliability
  • Extended equipment life
  • Lower rates of rejection
  • Reduced maintenance costs
  • Team Culture

Our approach has been evolved over years of field experience.

Whilst the basic building blocks of TPM remain unchanged, our approach addresses the areas where TPM was struggling to move from the classroom to the shop floor. We concentrate on the following key areas :

Criticality Assessment

This exercise is used to give us our starting point, essential for any Total Quality Programme. The exercise involves ranking your equipment into a priority sequence. Assets are ranked based on several factors, including impact on production quality, sensitivity to changeovers, knock on effect and cost.

We will drive this process to a formal meeting to reach consensus on the most critical items. The top 5 or 6 assets are targeted for pilot programmes.

This can later be incorporated as part of a Reliability Centred Maintenance study.

Overall Equipment Effectiveness

The next step is to give ourselves a means of measuring the progress of the programme. The OEE is a way of measuring how effective each individual piece of plant is, it relates defect free operating time to a theoretical ideal scenario. It is calculated for each piece of equipment as a function of availability, performance rate and quality rate.

The OEE is a very tangible measure, having visibility of it helps everyone see and understand the results of their efforts in moving towards a TPM culture and is a vital step in the project.

Conditioning Appraisal

Having identified the equipment to be focused on first, we need to bring that equipment to an acceptable base level before we start trying to pursue an ideal scenario. We need to establish the condition of the equipment and perform basic refurbishment where necessary.

We approach this in teams that will include everyone involved in using or maintaining the equipment in question, we will then hold a ‘Clean and check’ day. The key to this step is planning and preparation. All the necessary tools and equipment needs to be on hand, as well as spares, measuring instruments and check sheets.

Problem Solving

If we are going to adopt a TPM culture, we need to equip the users with the necessary tools to evaluate and then solve problems as they encounter them. There is a range of problem solving techniques that can be used, from control charts, to check sheets or cause and effect analysis. We will help you decide which of these are most appropriate and then put in place realistic training programmes. Training is often done one on one to avoid having to take groups of people off line for more formal workshops

Best Practice Implementation

It may seem obvious, but operating equipment outside its design parameters will almost certainly shorten the life of its components, and usually much more than in proportion to the degree of abuse. It is generally believed that the life of a machine decreases exponentially (in fact proportionately to the square) for each given increase in speed above the recommended level.

It is crucial to determine the correct operating parameters (speed, temperature, pressure etc.), to ensure that actual performance is monitored against these and that they are adhered to.

Asset Care Programmes

The specific programme for each machine will be decided on by the operators and maintainers. They need to decide what routines to apply, with what frequency and who is responsible.

Asset care is about moving from reactive to preventative maintenance, and about production understanding their responsibility for the life time cost of running an asset. If the operators take ownership for the prevention of failure, the incidence of breakdowns can be reduced dramatically, enabling maintenance to concentrate on prediction, planning and cost reduction techniques.

We offer full Computerised Maintenance Managements System that enable full monitoring.

The SACRED Philosophy

This is about creating a disciplined workplace. The concept is built around;

SORT - Get rid of anything unnecessary in the workspace

ARRANGE - The things you need, in the right place

CLEAN - Keep it clean and tidy

REPEAT - for Repeat the above for everything new arriving in the area - do I need it ? Put it in the right place, keep it tidy

EVERYTHING DISCIPLINE - Pass this discipline on to colleagues

Our Manufacturing consultancy on Total Productive Maintenace (TPM) is available in Lancashire and the Northwest and at short notice in Manchester, Blackburn, Preston, Liverpool, Burnley

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