TPM System | The production of the manufacturing facility directly depends on the quality of the equipment, products, and production lines. In the event of a breakdown, the failure of any tool, the entire production cycle may be stopped, which will cause damage to the company. To prevent the above scenarios and ensure high efficiency of continuous production, the TPM lean manufacturing system is widely used.
The specific approach is generally as follows:
The five principles of lean production, tool value stream and value stream map, waste, flow manufacturing, pull production system, continuous improvement (Kaizen) are integrated into the main means of TPM to improve overall equipment effectiveness (OEE).
The output (P-Production, Q-Quality), C-Cost, D-Delivery, Safety, and Morale of the whole system will be comprehensively improved.
TPM System – Equipment Maintenance
The LTPM (Lean total productive maintenance) system is a tool of the lean manufacturing concept. It is a methodology for the maintenance and improvement of production systems, in order to increase the efficiency of maintenance. The TPM is based on the principle of continuous improvement of production processes, due to autonomous and planned maintenance of critical equipment for the manufacturing facility.
The foundation of TPM production is based on the 5S system for the organization and rationalization of the workplace. This method consists of five steps:
- Sorting. Depending on the frequency of use of the tool, divide the items into groups and dispose of all the “unnecessary”.
- Keep things in order. Distribute items as conveniently as possible, ensuring targeted use and secure access to work objects.
- Keep clean. It is necessary to identify sources of pollution, develop an action plan to eliminate them, conduct regular inspection of equipment and cleaning at work.
- Standardization. Create step-by-step instructions for maintaining the order, cleaning schedules and control methods.
- Perfection. Support the process and principles for long-term application.
Why do TPM business need daily inspection of equipment?
The TPM consulting experts said that only the daily inspection of equipment is accurate and in place, and with maintenance and fixed repair, can eliminate hidden dangers of equipment, improve equipment performance, make equipment in good operating condition, and ensure the speed and accuracy of production.
The daily inspection of equipment is the responsibility of the operator.
The operator is the first responsible person and the main executor of the daily inspection and maintenance of the equipment.
Cleaning is the most basic work of daily inspection activities.
Neatness is the basic condition for the reliable operation of equipment. Cleaning is not simply for cleaning, but more importantly, through cleaning, stroking, and observing all parts and corners of the equipment, the potential defects or damage, temperature, sound and other abnormalities of the equipment are easy to find.
- Refueling : Means that the oil-filled parts of the equipment should be filled in time and the relative moving parts should always be kept in a good lubrication state. Keeping the machine in good, lubricated condition is a necessary guarantee to reduce breakdowns and extend the service life of the equipment!
Fastening refers to preventing equipment connections from loosening and falling off.
The vibration caused by a loose set of bolts and nuts often affects other connectors, even if the small vibration is not fastened in time, it will produce greater vibration of the equipment, and finally develop into various failures of the equipment.
Organize and rectify.
The sorting out of operator tasks is to clarify various operational tasks, correctly grasp various operation methods and procedures for discovering problems and dealing with problems and analyze the causes of problems. Rectification, on the other hand, is to observe and implement the standards that have been formulated.
- Adjustment can not only make the equipment run in the best state, but also avoid the expansion of equipment hidden dangers and the extension of deterioration. Simple adjustment work is the skill that the post operator must have and the specific implementation content. It is necessary to make appropriate adjustments to the operating actions and working conditions of the machine in time, and it is also an indispensable part of the operator’s reasonable use of equipment and correct operation of the equipment.
- For the normal operation of the equipment, it is an effective measure for the operator to be familiar with the equipment and master the equipment. Doing so allows the production personnel to complete the production task from the standpoint of managing the equipment.
Only a scientific, programmatic, and standardized inspection and maintenance system can ensure the safe and stable operation of equipment and provide material basis and necessary conditions for the safe production of Manufacturings. Spot inspection is the basis and foundation of equipment maintenance, and equipment maintenance and repair are based on equipment spot inspection.
Advantages of Lean TPM Management:
Lean TPM management can improve product quality
One of the supporting “8 pillars of TPM management” is quality maintenance, which integrates quality improvement into the production process. Play a TPM management role in the production process to improve product quality.
Lean TPM management can create a safe and efficient workshop production site
TPM management consists of a 5S activity base that ensures that all workspaces are always sorted, purchased, cleaned, and standardized, and eight support activities, all of which lead to a safer workplace. The focus on 5S and continuous maintenance of machinery makes the machine clean, healthy, and less likely to have loose problems; Create safe production conditions for clean equipment.
Lean TPM management can reduce unnecessary maintenance costs
TPM assigns work traditionally done by maintenance personnel to all plant personnel. In this way, everyone is responsible for the maintenance of machines and equipment. TPM regimes typically allow operators to perform basic manufacturing maintenance duties and cleaning regimes and encourage a proactive approach to identifying problems. This allows maintenance personnel to perform more value-added tasks.
Lean TPM management can improve the overall efficiency of equipment
The main purpose of TPM management is to improve the overall efficiency of equipment, in the final analysis, it is to prevent and eliminate factors that affect the company’s profitability, including constraints, consumption, etc., to achieve the company’s profits. After all, the core value of TPM itself will not change, but the times are changing, the way of profit is also changing, and TPM is constantly adapting to new changes.
TPM System
The TPM concept consists of eight pillars aimed at improving comprehensive service, increasing productivity and equipment life:
Offline service.
The TPM places the responsibility for the maintenance of the equipment on the workers who use it. This allows employees to examine the equipment, carry out cleaning and lubrication work in time, and eliminate the causes of breakdown.
Scheduled maintenance.
Regular inspection and prevention allow you to identify and eliminate the causes of equipment breakdown in time, as well as avoid downtime. TPM Lean Manufacturing recommends programmed maintenance that requires machines to stop after hours.
Quality service.
With the help of TPM, the production sets the highest quality standards and checks their compliance. This helps to ensure that any possible causes of defect-free manufacturing deviations are identified.
Continuous Improvement / Kaizen.
Total productive maintenance involves the organization of smaller groups of employees to achieve systematic incremental improvements in the operation of equipment. Small but multifunctional teams can identify and solve recurring problems.
Previously, hardware management
The practical knowledge gained through the TPM lean manufacturing approach is aim at improving and designing new equipment. This allows you to quickly bring new equipment to the ideal level of performance and make maintenance simple and reliable.
Employee training.
To achieve optimal performance and increase the level of competence of each employee, proper training is required. The concept of TPM involves conducting training to equip everyone with theoretical and practical knowledge. Otherwise, it is not possible to entrust each employee with routine maintenance or prevention.
Safety, health, environment.
Proper TPM of equipment and buildings will help reduce the number of accidents at work and organize safe workplaces for employees.
TPM in offices.
The TPM lean manufacturing system is primarily focused on production, but it is important to apply it to administrative departments. After all, it is managers who most often manage production processes. This eighth pillar is aimed at providing the right information in the right form in the right place with the lowest possible cost. This includes streamlining workflows, removing redundant archives, and training employees.
Using a TPM system helps to get rid of the following types of losses:
- Idling and minor faults.
- Failure.
- High installation and readjustment time.
- Speed reduction.
- Connecting and alteration.
- Launch losses.
Quite often, for the effective elimination of all types of losses in conjunction with total productive maintenance, the SMED method is used, which is also an integral part of lean production. SMED system consists in quick readjustment of equipment, thereby reducing the loss of time when switching from one size to another, or one product to another.
What causes makes TPM ineffective?
The TPM consulting experts said that many companies are not satisfactory after the implementation of TPM management model, and do not know the problems, in fact, many companies have fallen into several misunderstandings, so the effect is not satisfactory.
1. Believe that employees resist transformation
In general, most people like stability and don’t like to step out of their comfort zone, so employees don’t like transitions. But most of them can embrace the transition if they can be part of the transformation process. The difficulty is that when new project improvement initiatives are introduce into data analysis, employee engagement is abandon.
For example, workers in processing plants often find opportunities to improve planning and production scheduling, but most react instinctively. They are reluctant to work according to strict stereotypes, such as a detailing work plan for the next three days. Improvement planning and production scheduling must be carrying out by cultural and artistic transformation, as well as the main steps and processes agree by all. Even though we know this, the processing plant is still not calm when it comes to actually dealing with this problem. Not only did they drink tea and talk about how to improve, but they also sent two or three planners to sign up for a two-day program and production scheduling course.
2. Think that maintenance personnel have more shifts, and the less equipment downtime, the better
If the processing plant has a lot of work tasks, it does require a large number of workers to rotate to maintain common equipment failures. When you encounter a similar situation in a processing plant, it means that you do not have symptomatic treatment. To solve the many problems existing in processing plants, the root cause of the problem must first be identify and solve. So, what’s a good way to be purposeful? In most cases, you’re inherently flawless at fixing the various mechanical faults you find, and you’re not always able to predict problems before common failures occur. So you have to have a lot of people, right? In the short term, this will be the case, but it will be superfluous, especially from a long-term perspective.
3. It is believed that the degree of harm of mechanical failure is affected by the frequency of investigation
In general, the inspection frequency of processing plant parts is based on the analysis and study of the degree of damage caused by mechanical failure. First, the damage detection frequency for mechanical faults is actually valid in the application scenario, but let’s look at an example to prove that the material is not entirely correct.
It is assume that the screw inspection frequency of ordinary parts has been determine. The role of the difficult screw is to maintain the tightness of the air pump. Depending on the scientific research of the degree of damage, the air pump and seal are very important.
In general, the parts with the most damage scores are inspect several times per vehicle. The screws of each car have to be check many times, and you instinctively feel unreasonable, why? Because the frequency of inspection should be determine base on the common failure time of the parts in the field. The screws in the above case are not prone to common failures when the two trains are alternating, otherwise it would be an absurd random event.
Zero Defect Concept
That is to say, in order to establish the “zero defect” operation of mechanical equipment, it is necessary to appropriately formulate the index values of new projects and management methods for each management method, so that all personnel can participate in the maintenance of protective equipment in a directional and confident way beyond the target value; In order to ensure the quality of work, operating procedures, timely handling of potential safety hazards, common faults and proper handling, the supervision and management system ensures production safety. The incentive mechanism is a continuous driving force, rewards and punishments are paid. So that leading cadres and employees can see the effectiveness of TPM management, so that TPM process equipment maintenance has been widely and continuously apply.
TPM equipment maintenance is a powerful method of improving the efficiency of your equipment and production processes. It introduces a structured approach to service and quality control, develops ideas for technical and preventive maintenance, involving all departments and people of the organization.