August 9, 2015

Total Productive Maintenance (TPM): Preventive Maintenance Corrective Maintenance Inbuilt Maintenance

Resource: Total Productive Maintenance, Goal, Main Aspects, Preventive Corrective Inbuilt  Maintenance

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TPM or we will say Total Productive Maintenance, philosophy is mostly oriented from manufacturing industry and this page will explain aspect of TPM according to that. But be curious and think of ways, it can be implemented to different industry sectors. One classic example will be software industry.

Total Productive Maintenance
• Reasons for throughput losses on Machinery
Breakdown: Failed function and reduced function.
Setup and Changeover: Taking much longer than needed
Idling and minor stoppage: Sudden disruption
Reduced speed: Actual vs. designed
Quality defects and rework: Sporadic and chronic
Startup yield: Process instability

Goal of Total Productive Maintenance (TPM)
• The goal of TPM is to minimize downtime due to maintenance, and maximize machine uptime.

Importance of TPM
As buffer sizes and inventory levels are reduced, the uptime on the machinery becomes even more important. Because there is little inventory to buffer unplanned downtime in a lean environment, when a machine goes down the entire production line may go down; therefore, a formal TPM program is instrumental in supporting a lean manufacturing implementation.

Main Aspects of TPM
• Preventive Maintenance
• Corrective Maintenance
• Inbuilt Maintenance

Preventive Maintenance
• Preventive maintenance is concerned with the uptime or availability of equipment. The effort here is aimed at performing preventive maintenance action on equipment in a planned / scheduled and disciplined manner, as opposed to in an unplanned or chaotic manner.
• The operators are a central part of this program, specifically to conduct daily maintenance on the equipment and identify abnormalities as they occur. This is paramount to successful preventive
maintenance

Corrective Maintenance
Corrective maintenance concentrates on enhancing frequently failing equipment. The  idea here is that if components from the original equipment keep breaking, why not replace them with something better?

In‐built Maintenance
• Maintenance prevention is an area that most of companies neglect and pay very little attention to when designing or purchasing new equipment. Because one of the key ingredients of a successful TPM program is that of daily operator “autonomous maintenance”, it is imperative that equipment be easy to maintain on a recurring basis. If the new machinery is difficult to lubricate, if the bolts are difficult to tighten, and if it is impossible or difficult to check critical fluid levels, then it is very unlikely that operators will be motivated to monitor the equipment
on daily basis. The total life‐cycle cost on the equipment must be examined when Procuring new machines not Week #6 9 machines, just the one‐off, nonrecurring costs

Like wise, goal of TPM for our software example will be minimize software downtime due to maintenance, and maximize  uptime and their are steps you can follow through the process.