The total productive maintenance checklist aims to eliminate breakdowns, defects, and slow runs of production equipment. The checklist is used to assess whether a company is following the TPM program.
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A total productive maintenance process follows the 5s methodology introduced and developed in Japan around the 1960s. The 5s are:
Following these principles, a total productive maintenance (TPM) checklist is used to assess a company’s progress toward achieving its goal in proper equipment maintenance. Manufacturing or production companies can assess cleaning levels, sources of contamination, involvement of team members, and more by following a structured checklist and taking required actions from there.
A TPM checklist ensures that all team members understand, maintain, and improve the integrity of production and quality systems. By applying the principles of TPM, the company will achieve a continuous production cycle without any breakdowns.
The eight pillars of TPM focus on preventive and proactive procedures to improve equipment reliability. TPM strives for perfect production, which translates to:
In order to achieve these goals, it is important to base your production cycle on a solid base of structured tasks and principles that are outlined in the following 8 axioms:
The implementation of total productive maintenance principles will optimize work schedules, produce efficient employees, create a cleaner and safer work environment, achieve equipment reliability, and save you money. It is a program that is designed for a holisitic approach to productivity by paying attention to all of the branches influencing a production cycle, including management and administration down to the very basic principles of health and safety of employees.
Here’s how to implement these principles in the workplace:
Choose an area where you can start applying TPM principles first. Once employees see the benefits of the process, they will be more accepting of the new style of process. Include employees from different departments during the pilot process and create a project board so they can visualize where they’re going.
When looking for a pilot area, you should ask these three questions:
The concept of this principle focuses on the 5s system and autonomous maintenance. Operators should first learn how to consistently keep the machine in its optimum condition using the 5s program: by being organized, clean, orderly, using standardized and sustainable methods.
This step requires tracking the overall equipment effectiveness (OEE) of the target machine. Monitoring and measuring OEE provides a data-driven confirmation on whether your TPM program is effective or not. More so, it tracks your overall program as well and gives you a general idea of your efficiency.
After you have a data-driven overview of where your top bottlenecks and losses are, address them immediately. Start by organizing a cross-functional team of operators, supervisors, and maintenance personnel to delve into the OEE data initiating a root cause analysis to identify the main cause of the losses.
Choose which parts should receive proactive maintenance by looking at these three elements:
After that, employ proactive maintenance intervals. These intervals are flexible and can (and should!) be adjusted whenever necessary.
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