Last updated on 2024年6月30日

How do you adapt TPM and lean manufacturing to different types and sizes of industries and markets?

由人工智能和领英社区提供技术支持

本文章的要点总结

Customize implementation:

Tailoring the Total Productive Maintenance (TPM) pillars to fit your industry, such as starting with autonomous maintenance and focusing on specific equipment, ensures a better fit for your unique context.
Model machine approach:

Select a single machine or cell as a pilot for TPM and lean practices. Begin with 5S organization and tackle abnormalities systematically. This creates a template for wider implementation that's grounded in real-world success.

本摘要由 AI 和以下专家提供支持

Ramesh P.R.

CEO- Corporate Consulting Division.…
Sanjeev Kulkarni

Vice President - Automotive (BU) India…

1 Assess your current state

The first step to adapt TPM and lean manufacturing is to understand your current situation and identify the gaps and opportunities for improvement. You can use various tools and methods to assess your current state, such as value stream mapping, gemba walks, 5S audits, OEE analysis, waste identification, and customer feedback. The goal is to have a clear picture of your value streams, your key performance indicators, your sources of variation and losses, and your customer needs and expectations.

添加您的观点

Eduardo Riady Hazbún

Gerente Operaciones - Gerente Supply Chain - Gerente Comercial - Industrial - Manufactura - Packaging - Servicios
举报内容
Levantar condiciones actuales con indicadores o KPI que sean representativos, para construir esta información puede: - medir productividades - medir tiempos muertos o para por desperfectos - medir tiempos de configuraciones Realizar una caminata gemba aportará mucho a esto ya que puede: - Observar el proceso - Entender cómo se desarrolla el trabajo - Hacer preguntas - Aprender para mejorar los procesos - Hablar con las personas que generan valor para el proyecto - Determinar dónde se enfoca el valor y dónde hay desperdicios - Observar y preguntar a los empleados por sus tareas - Identificar mejoras de productividad - Observar las medidas de seguridad de un proyecto - Determinar las áreas de mejora en la seguridad de los empleados

已翻译

赞
Senthil Kumar V

Unit Head @ Ola Electric | Process, Quality, Material & People Management
举报内容
Offcourse these are fundamentals to get into TPM & Lean Manufacturing. Need to have a Best Awareness program to all in the Supply Chain.

已翻译

赞

2 Define your goals and priorities

The next step is to define your goals and priorities based on your current state assessment and your strategic vision. You should align your goals and priorities with your customer value proposition, your competitive advantage, and your market requirements. You should also set SMART (Specific, Measurable, Achievable, Relevant, and Time-bound) objectives and targets for each value stream, process, and equipment. Your goals and priorities should guide your action plan and resource allocation.

添加您的观点

Eduardo Riady Hazbún

Gerente Operaciones - Gerente Supply Chain - Gerente Comercial - Industrial - Manufactura - Packaging - Servicios
(已编辑)
举报内容
Una vez levantados sus objetivos, debe trazar una línea de trabajo que se alinee con los objetivos estratégicos de la compa?ía y con los de sus clientes. Debe definir como logrará obtener una ventaja competitiva respecto a su competencia, como agregará valor a su producto y como se mantiene al tope del mercado con su oferta de valor. Ideal poder tener el triángulo del éxito: Precio competetivo, Pronta entrega y Calidad. Con esto se ganó el cielo con los clientes. Si quiere agregarle una cuarta pata a la mesa: Innovación constante

已翻译

赞

3 Implement the TPM pillars

The third step is to implement the TPM pillars, the core elements of the TPM approach. These include autonomous maintenance, which empowers operators to perform basic maintenance tasks, such as cleaning and lubricating their equipment; planned maintenance, which optimizes preventive and predictive maintenance activities; quality maintenance, which prevents defects and errors by addressing root causes; focused improvement, which engages cross-functional teams to solve chronic and complex problems; early equipment management, which designs and installs new or modified equipment with high reliability; training and education, which develops the skills and knowledge of all employees; safety, health, and environment, which ensures a safe workplace by eliminating hazards and risks; and TPM in administration, which applies TPM principles to administrative functions such as finance and human resources.

添加您的观点

Eduardo Riady Hazbún

Gerente Operaciones - Gerente Supply Chain - Gerente Comercial - Industrial - Manufactura - Packaging - Servicios
(已编辑)
举报内容
Los 8 pilares del TPM: 1) Mejora Enfocada 2) Mantenimiento Autónomo 3) Mantenimiento Planificado 4) Mantenimiento de Calidad 5) Prevención del mantenimiento 6) Actividades de Departamentos Administrativos y de Apoyo 7) Capacitación y Formación 8) Gestión de seguridad y Entorno Para implementar esto debe formar equipos y líderes comprometidos en cada uno de los pilares, mostrándoles las bondades del TPM y las mejoras que se pueden obtener a partir de esta filosofía de trabajo. Invítelos a hacerlo parte de su vida; las 5s, el orden, la reutilización, el reciclaje, el botar lo que no se usa, etc. De esta manera ellos verán ventajas mas allá de su trabajo y lo llevarán a su vida personal. Con esto los comprometerá aún mas en su objetivo y metas

已翻译

赞

4 Apply the lean principles

The fourth step is to apply the lean principles, which are the foundation of the lean manufacturing approach. To start, you must specify value and define what it means to your customers and how you deliver it through your products or services. Next, you must identify the value stream and map the flow of materials, information, and activities from the raw materials to the finished products or services. Then, you must eliminate waste by removing any non-value-added steps or resources from your value stream. After that, you should create a smooth and continuous flow of value from the beginning to the end of your value stream without interruptions or bottlenecks. Additionally, you should produce or deliver only what your customers demand when they demand it in the right quantity and quality. Finally, continuously monitor, measure, and improve your value stream performance, quality, and customer satisfaction.

添加您的观点

5 Adapt to your context

When adapting the TPM and lean manufacturing approaches to your specific context, such as industry type, market size, product complexity, customer diversity, and organizational culture, you should consider the level of customization and standardization of your products or services, the degree of automation and human involvement in your processes, the frequency and variability of customer demand and feedback, the availability and reliability of your suppliers and partners, the maturity and readiness of your employees and managers, as well as the alignment and communication of your vision and values.

添加您的观点

Asanka Chathuranga MBA, BSc.(Eng.), CLSSBB

10+ Years of Experience in improving manufacturing results as a Continuous Improvement Manager | Certified Lean Six Sigma Black Belt | Production Engineer | Maintenance Strategist
举报内容
I would say, the benefits and applicability of TPM is higher when you have equipment intensive operations as in process industries and automated lines as TPM more focused on equipment. Irrespective of the size it can be applied. Lean deployment is applicable to a larger scope in this context across industries, specially when the organizations are bigger where becoming lean is inevitable. The power of lean is applicable irrespective of it is human-intensive operation or machine-intensive. It's a broader approach, but the above is just a major part of it.

已翻译

赞

6 Sustain and improve

The final step is to sustain and improve the results of your TPM and lean manufacturing initiatives. Establishing a culture of continuous improvement and learning, where everyone is committed to achieving excellence and solving problems, is essential. You should also use various tools and methods to sustain and improve your performance, such as visual management, standard work, kaizen, gemba, and hoshin kanri. Visual management uses signs, charts, boards, and colors to display the status, progress, and performance of value streams, processes, and equipment. Standard work documents and follows best practices for each task, activity, and role. Kaizen implements small and frequent improvements based on employee feedback. Gemba visits the actual place where work is done to observe and improve reality. Hoshin Kanri aligns strategic goals with all levels of the organization and ensures their execution and review.

添加您的观点

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

添加您的观点

Ramesh P.R.

CEO- Corporate Consulting Division. "Helping organizations in Business transformation through Customized Solutions" Certified LSS MBB I PMP I TPM Facilitator I Lean Coach. Deputy Chair - ASQ India Section
举报内容
TPM complements lean by improving Stability of equipment. Irrespective of Industries we can use both concepts together for Operational excellence

已翻译

赞
Sanjeev Kulkarni

Vice President - Automotive (BU) India at Harman International India Pvt Ltd
举报内容
My experince of TPM: 1.Management committement, Organization wide training(CEO to Operators) 2.5S training and Implementation 3.First focus on 4 pillars , JH, PM/KH, KK and Quality Pillar 4.Select Model machine/cell this can be old machine or workstation of the plant. 5.Start with 5S and JH in model machine. There are 16 losses, first start with identification of all types of abnormalities through tagging (Unique colour Tag per abnormalities) 6.Once abnormalities are closed, check before & after scenario 7.While closing abnormalities, do the why-why analysis to arrive at root cause.Actions based on RC will lead learnings 8.Standardize learnings by updating DM, PM&CP plans 9.Repeat 1-8,steps to implement improvements across plant

已翻译

赞
Balaji L R

60K+ Followers | Quality Manager | EV | Automotive | Problem Solving | APQP | PPAP | Six Sigma - GB | QMS | ISO 9001 | IATF 16949
举报内容
Safety First, Always:The Crucial Role of TPM in Ensuring Safety In the world of manufacturing, safety is not just a priority; it's a necessity.Total Productive Maintenance (TPM) plays a pivotal role in ensuring safety in manufacturing.

已翻译

赞

Total Productive Maintenance (TPM)

+ 关注

给文章评分

我们借助人工智能创建了此文章。您认为这篇文章怎么样？

很棒不太好

举报此文章

查看全部

How do you adapt TPM and lean manufacturing to different types and sizes of industries and markets?

1

2

3

4

5

6

7

1 Assess your current state

2 Define your goals and priorities

3 Implement the TPM pillars

4 Apply the lean principles

5 Adapt to your context

6 Sustain and improve

7 Here’s what else to consider

Total Productive Maintenance (TPM)

给文章评分

感谢您的反馈

更多Total Productive Maintenance (TPM)相关文章

更多相关阅读内容