What is Total Productive Maintenance?
What is TPM? Total Productive Maintenance is a lean manufacturing approach that drives continuous improvement and is based on the idea that not just the maintenance team rather everybody in the manufacturing facility should take part in maintenance activities. Total productive maintenance (TPM) maximise equipment effectiveness through actively involving all supporting departments and continuously monitoring their operations. The ultimate goal of TPM is to optimise equipment availability and improve overall productivity.
What are the advantages of TPM?
TPM standardise and organise overall procedures and benefits both workplace and production quality. There are numerous benefits that the organisation experience once they deploy the TPM strategy, including and are not limited to;
- Fewer Breakdowns
- Safer Workplace
- Increase in Productivity
- Better Overall Performance
- Less Unplanned Maintenance
- Lower Manufacturing Costs
- Increased Customer Satisfaction
- Complete Utilisation of Equipment
- Increased Equipment Lifespan
5S - The Foundation of TPM
TPM is built upon the 5S foundation, a lean tool that transforms the workplace into a more stable and organised system. An organised workplace paves the way for an efficient, productive and safer environment. The five ‘S’ stands for;
Red tag and eliminate what is not necessary at work. It identifies the redundancies and enables the team to initiate action plans for their disposal.
Everything will be allotted specific storage space for easy access, creating an organised workplace where they find what they need.
The workplace must always be kept clean as it will ease the maintenance operations that ought to occur.
Standardise the overall process at the workplace to maintain order and cleanliness.
Ensure that each step is performed regularly and with utmost care to create an environment of continuous improvement.
TITAN CMMS - The Key to Optimise Maintenance Operations Smart Solution
Worried about managing maintenance operations? TITAN CMMS is here to help! TITAN help organisations track and manage all maintenance-related tasks, boosts asset efficiency and performance, by creating a maintenance request, breakdown request, just do it (JDI), and tasks, at any time from anywhere.Start Free Trial Watch Video Tell a Friend
CMMS & The 8 Pillars of TPM
The pillars of Total Productive Maintenance is built upon the foundation that the 5S lean tool creates in a work environment. Let us see how CMMS plays a role in TPM deployment
In Autonomous Maintenance, the machine operators take responsibility for maintenance tasks that effectively use their skills. When maintenance-related actions like safety checks, lubrication and cleaning are done by machine operators, maintenance technicians will concentrate on more complicated maintenance tasks.
How does CMMS help? - CMMS classifies maintenance tasks the skills required to do the task and lists those who are eligible to execute the task and assign them.
Focused Improvement identifies and eliminates losses commonly encountered in manufacturing processes; as a result, the organisation can increase OEE and improve the efficiency and quality of its operations along with guaranteed minimal losses within the production process.
How does CMMS help? - The historical data of assets provided by CMMS software will help the maintenance department realise inefficiencies and enable them to implement improvement strategies.
Planned or preventive maintenance is considered the best way to avoid breakdowns and machine downtime. It aims at improving the effectiveness of equipment by scheduling maintenance tasks to keep every asset up and running to its total efficiency.
How does CMMS help? - Using CMMS software, organisations can plan, schedule and track preventive maintenance activities and ensure they are executed on time. This helps in reducing unplanned and costly downtime.
Quality management in TPM is all about zero defective products and increased customer satisfaction. Addressing equipment quality issues and implementing countermeasures will eliminate the recurrence of defects. This will result in producing high-quality products every single time.
How does CMMS help? - A well maintained PM schedule means high-quality products, and CMMS easily track the maintenance schedule and deploy PM strategies on time.
The objective of Early equipment maintenance (EEM) is to reduce the Life Cycle Cost of equipment. Designing a new machine by incorporating the inputs of those who use it will increase reliability, operability, maintainability, and safety and reduce breakdowns and maintenance efforts.
How does CMMS help? - Historical data stored in CMMS software will help technicians review the overall performance of equipment by analysing the frequency of breakdown/repairs and further initiate plans to remove any kind of anomalies.
Learning & Development
Learning and development are essential in TPM as they will help technicians build basic maintenance knowledge and keep a regular check on equipment. It ensures that technicians are well aware of the new machinery and its maintenance operations.
How does CMMS help? - CMMS keeps track of the learning and development process, sends notifications to technicians on new maintenance operations, and ensures that they are updated with the latest information to address any scenario.
Administrative & Office TPM
TPM also addresses and eliminates areas of waste in administrative functions. Everyone must be focused on making improvements and reducing waste in their operations, improving overall process efficiency from top to bottom.
How does CMMS help? - CMMS acts as a unified platform for both the maintenance and administration departments. It is necessary to have a smooth workflow as both are an integral part of maintenance operations.
Safety, Health & Environment
Good maintenance management ensures that the environment is safe and secure and eliminates all unsafe conditions by identifying the root cause of accidents and taking necessary steps to prevent its re-occurrence.
How does CMMS help? - CMMS stores information on safety, health and environment and ensures that all processes are aligned with the health and safety regulations.
CMMS & TPM Mobile App
The combination of CMMS and TPM mobile app provides; faster execution systems, reduced error rates, improved efficiency, an enhanced lifetime of machinery, failure prediction, zero downtime and increased quality output. Gain full control of maintenance activities, work orders and other operations from wherever you are through your smartphones and analyse trends and reports to make data-driven decisions.
Frequently Asked Questions
- Unplanned Stops
- Planned Stops
- Small Stops
- Slow Cycles
- Production Defects
- Startup Defects