What is Total Productive Maintenance?
Total Productive Maintenance (TPM) is an integrated approach to obtain a higher performance in production, more reliable equipment and a higher knowledge of the operator. This is obtained by:
- Maximising the overall equipment effectiveness.
- Establishing a thorough system of preventive maintenance for the equipment's entire life span.
- Implementing TPM by involving all functions, e.g. engineering, operations, maintenance.
- Involving every single employee, from top management to workers on the floor.
- Establishing autonomous maintenance activities for operators.
The word "total" has three meanings that describe the principal features of Total Productive Maintenance (TPM):
- Total effectiveness indicates TPM's pursuit of economic efficiency or profitability.
- Total maintenance system includes maintenance prevention and corrective maintenance as well as preventive maintenance.
- Total participation of all employees includes autonomous maintenance by operators through small group activities.
How does Stanwick help you in implementing Total Productive Maintenance?
Stanwick developed a roadmap and appropriate tools & techniques in order to implement Total Productive Maintenance or TPM. Operators and maintenance technicians are highly involved during implementation ; operators will be involved in maintenance activities and technicians will train and assist production operators.
We execute a TPM audit according to the four developmental stages (breakdown maintenance, preventive maintenance, productive maintenance, Total Productive maintenance) and identify the potential losses and improvement areas.
We customise the TPM roadmap according to your specific needs, install the project organisation and provide training in the different tools and approaches. The TPM roadmap will typically consist of 6 major areas:
- Improving the overall equipment effectiveness (OEE): identifying and eliminating the 8 major wastes, reduce set-up times (SMED), PM analysis, Quality maintenance, Poka-Yoke.
- Improving the overall operator effectiveness by detailed activity analysis and introducing increased operator and team autonomy.
- Introducing autonomous maintenance based on the 5S principles.
- Setting up a planned maintenance strategy: implement a maintenance management information system, introducing preventive maintenance, spare part management and predictive maintenance systems.
- Focus on early equipment management: life cycle costing (LCC), failure mode and effect analysis (FMEA), maintenance prevention.
- Set up a team based approach in the maintenance organisation: clear performance indicators, creation of polyvalent technicians, focus on flawless collaboration with production, visualisation and autonomy.
We assist you during the implementation of the project.
We provide assistance in the monitoring and reporting of progress to management.
Recent client projects: Recticel, Philips, Scott Continental, Terumo, Umicore
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