With introduction to the foundation (5-S system) and 8 pillars on which the TPM process is built , the implementation of TPM program needs to be understood. This is generally done in 6 steps: 1) share your plans with the entire organization 2) identifying a pilot area, 3) restoring equipment to prime operating condition, 4) measuring OEE, 5) addressing and reducing major losses, and 6) implementing planned maintenance. Step 1: Share your plans with your entire organization Implementation of TPM starts with introduction of the program, creating awareness and understands the objectives and value it generates within the organisation. But above all it’s critical that management and supervisors grasp the importance of proper TPM procedures. If managers promote, introduce, and adopt a certain way of working, then shop-floor personnel will generally embrace plans much faster. Step 2: Identify a Pilot Area Identifying a work area, or a plant, or an equipment where the production process operat...

The Total Productive Maintenance Total Productive Maintenance (TPM) is a system of maintaining and improving the integrity of production, safety and quality systems through the machines, equipment, processes, and employees morale and job satisfaction that add business value to an organization. The dual goals of TPM are zero breakdowns and zero defects; this obviously improves equipment efficiency rates and reduces costs. It also minimises inventory costs associated with spare parts.  Total Productive Maintenance (TPM) was developed by Seiichi Nakajima in Japan between 1950 and 1970. This experience led to the recognition that a leadership mindset engaging front line teams in small group improvement activity is an essential element of effective operation. The outcome of his work was the application of the TPM process in 1971. Nippon Denso (now Denso), a company that created parts for Toyota, was one of the first organizations to implement a TPM program. This resulted in an internati...

Maintenance The maintenance concept is the comprehensive description of the maintenance constraints, considerations as well as plans to provide support to the operations of the system or equipment in the development process. The concept of maintenance of a system or equipment is derived from the operational concepts and the operation is the major driver in the design and support of the system. Furthermore, the requirements of the maintenance concepts are translated into the support requirements and system design. The maintenance concept continues to come into a form the decisions of the design system, as well as the product support requirements and the detailed maintenance as the activities of the system design, are completed (Waeyenbergh & Pintelon, 2002). At the time of developing the maintenance concept of the system, some important guidelines must be considered which are provided below: The overall general repair policies like the criteria of repair or replacement of equi...