How do you use TPM to reduce waste, downtime, defects, and accidents in your manufacturing processes?

El Mantenimiento Productivo Total (TPM) es un sistema de mejora continua basado en un concepto de origen japonés, que se centra en el mantenimiento y funcionamiento de los equipos. Se basa en la idea de que todos los empleados deben participar en el mantenimiento de su propio entorno de trabajo. Esto significa que los miembros de los equipos individuales de todos los niveles de gestión deben participar en inspecciones periódicas, mantenimiento preventivo y sistemas de revisión de cualquier equipo utilizado en el trabajo.

Having a daily/weekly checklist utilized by your operators will help identify safety concerns, fluid levels and machine leaks which and can lead to injuries, machine failures and performance issues. The frequency should be daily or every shift if a critical aspect such as safety or levels and weekly for aspects that are less critical. The ability to collect data to identify trends is beneficial to help see gradual wear and tear that can lead to failure. Having good reference documents such as Gemba Docs or excerpts from machine manuals for the operators to verify against is best practice.

TPM for wide-implementation is not only about "maintenance" only, not only for machines / equipment. In big cooperate company such as Heineken, TPM includes Quality, Safety, Environment, Sustainabilty, Maintenance, Production, Logistics. Therefore, you could use methodology to apply in any session you are working at. TPM need to be stanadardized in standard checklist of actions and specific for each company since every company will be different in size, production equipment, land, people, etc. This will help implementors at each department to do in the right way, that's role of TPM Manager need to do.

Beneficios de Implementar TPM Menor Tiempo de Inactividad: El mantenimiento preventivo y predictivo reduce las paradas no planificadas, mejorando la disponibilidad de los equipos. Menos Defectos: La mejora continua y el control de calidad aseguran que los productos cumplan con los estándares requeridos. Reducción de Accidentes: La capacitación y las prácticas seguras disminuyen los riesgos laborales. En la práctica, TPM implica un cambio cultural en la organización, donde todos los empleados se sienten responsables del mantenimiento y la mejora de sus equipos y procesos. Esto no solo mejora la eficiencia y la calidad, sino que también fomenta un ambiente de trabajo más seguro y colaborativo.

1. Implement Preventive Maintenance: Schedule regular equipment checks to prevent unexpected breakdowns. 2. Engage Operators: Train operators to perform basic maintenance and identify potential issues early. 3. Conduct Root Cause Analysis: Investigate and address the underlying causes of defects and downtime. 4. Standardize Procedures: Develop and follow standardized work procedures to ensure consistency and reduce errors. 5. Monitor Performance Metrics: Use data to track equipment efficiency and identify areas for improvement. 6. Foster Continuous Improvement: Encourage regular feedback and suggestions for process enhancements.

TPM strives for total perfection no breakdowns, no defects, no accidents by positioning maintenance as a core, value-added function rather than a cost center. It promotes a sense of belonging, which is key to guaranteeing the care of the equipment. there is also an aspect that values the involvement of everyone to increase the quality of manufactured products and ensure "zero breaks", "zero defects" and "zero accidents".

na minha opni?o, um dos principais benefícios do TPM (Total Productive Maintenance) incluem a redu??o de paradas n?o programadas de máquinas, o aumento da eficiência operacional e a melhoria da qualidade dos produtos. Isso impacta positivamente o OEE (Overall Equipment Effectiveness), aumentando sua taxa ao otimizar o tempo de produ??o, minimizar perdas e maximizar o tempo de opera??o efetiva das máquinas.

Alguna de las ventajas que puede aportar una correcta implementación de TPM son: - Libera espacio físico - Mejora la disponibilidad de los equipos - Mejora la calidad del producto fabricado - Mejora los tiempos de entrega - Reduce costos de producción - Reduce costos de mantenimiento Todo esto se reduce a aumentar las utilidades de la compa?ía, ademas de tener motivados a los colaboradores y a la larga tener menor rotación del personal involucrado, ya que se sientes una parte importante de la compa?ía.

TPM may help your manufacturing processes in a number of ways, including lowering waste of energy, materials, time, and space; averting unplanned pauses and disruptions; guaranteeing the consistency and quality of your goods; and safeguarding the health and safety of your employees. TPM assists you in achieving this by reducing setup and changeover times, removing errors and rework, preserving and enhancing accuracy,

Pues la base de cualquier sistema pasa por 5’s o ahora también llamada 6’s donde la última es relativa a la seguridad y en mi capacitación en TOYOTA, decían el Mecánico de servicio en la agencia debe ser capaz de encontrar una herramienta con los ojos cerrados

By fostering a culture of ownership and preventive care, TPM empowers employees to identify potential problems before they occur. Furthermore, TPM's focus on "mistake-proofing" (poka-yoke) through automation or visual cues significantly reduces defects. The result? Increased production uptime, improved product quality, and a safer work environment. The future of TPM lies in harnessing data and automation. Sensor-equipped machines can continuously monitor their health, sending real-time data for predictive maintenance. Advanced analytics can identify trends and predict potential issues before they snowball into major problems.

na minha opni?o, para implantar o TPM de forma eficaz, é essencial envolver todos os níveis da organiza??o, desde a lideran?a até os operadores de máquinas, promovendo uma cultura de responsabilidade compartilhada pela manuten??o preventiva. Estabelecer metas claras e mensuráveis, oferecer treinamentos regulares para capacitar os colaboradores e implementar sistemas de monitoramento e acompanhamento s?o passos cruciais.

TPM es una implementación que cambia la manera de trabajar de los colaboradores, es un cambio de hábito, ya que involucra cambio progresivo, continuo y de largo plazo. Para implementar TPM, la alta dirección debe nombrar un equipo directivo, definir la visión de TPM y nombras los equipos de trabajo. Se deben realizar auditorías y evaluaciones períodicas y trabajar los 8 pilares de TPM: - Mantenimiento autónomo - Mantenimiento planificado - Mantenimiento de calidad - Mejora enfocada - Gestión temprana de equipos - Educación y capacitación - Seguridad, salud y medio ambiente - Administración de TPM Durante la implementación debe hacer seguimiento a las labores realizadas verificando la eficacia del trabajo desempe?ado.

Um fator que deu muito certo nas implementa??es que já fizemos, foram: 1- Apoio Incondicional da Alta Gest?o. 2- Tratar o pilar Educa??o e Treinamento inicialmente como BASE, ALICERCE. Um time bem treinado e engajado, que compre a ideia do líder e da Alta Gest?o! Partindo desses pressupostos, as etapas que sucedem ser?o bem-sucedidas.

To reduce waste in production start with measuring all the waste source then analysis the data to be able prioritize which source that have a big waste contribution then root cause analysis to find out the cause then plan the actions, monitor the actions and measure the decrease of the waste. Contribution of all related team would give huge impact on this project

In addition to the structured steps and pillars outlined for TPM implementation, it's important to highlight the role of leadership in driving success. Leaders play a crucial role in setting the tone, providing resources, and championing the TPM journey within an organization. Their commitment to fostering a culture of continuous improvement and empowering employees to take ownership of maintenance processes is instrumental in realizing the full potential of TPM.

TPM are very detail approach from every single pillars & godd to be implemented as the foundation. For the companies that have no strong organization structure, Lean will be more simple to be inplemented & bring faster impact.

Além dos passos essenciais para implementar o TPM, é importante considerar alguns pontos adicionais: 1. **Envolvimento e comprometimento da lideran?a** 2. **Cultura organizacional** 3. **Treinamento e capacita??o** 4. **Comunica??o eficaz** 5. **Avalia??o e melhoria contínua** Considerando esses aspectos adicionais, você estará melhor preparado para implementar e sustentar com sucesso o TPM em sua organiza??o.

O apoio incondicional da alta gest?o é crucial para o sucesso do TPM, pois garante a aloca??o de recursos necessários, promove uma cultura de melhoria contínua e motiva todos os níveis da organiza??o a aderirem às práticas de manuten??o produtiva, resultando em melhorias significativas na eficiência, qualidade e seguran?a dos processos industriais.

O TPM é uma estratégia abrangente que transforma a maneira como as empresas gerenciam seus equipamentos e processos, promovendo um ambiente de alta eficiência, qualidade e seguran?a. Sua implementa??o eficaz pode levar a melhorias significativas na produtividade e competitividade da organiza??o.