What are the best practices for implementing TPM in different stages of equipment life cycle?

In my openion. The design and procurement stage itself the company need to accompany the maintenance team into the process and study the possibility of maintenance activities and they will think ahead to the maintenance and reliability portion of the equipments life cycle.

Todo lo que se pueda detectar, evaluar, mejorar, corregir, en la etapa de dise?o de un equipo o un proceso, contribuye de manera significativa en su mejor desempe?o en la etapa productiva. En tal sentido una parte importante de esta estrategia es plantear desde el mismo comienzo las inspecciones y mantenimiento de primer nivel TPM por los operadores, y las preventivas con especialistas, para asegurar el mantenimiento y la aplicacion de la mejora continua en toda oportunidad que se encuentre.

One thing I learned when purchasing new equipment is to get a 3-6mo. Guarantee from the company that manufactured it in case there are hiccups and/or the operators/mechanics discover that something doesn't work as it should and having the support of the manufacturer not only helps you, but also can help them make improvements.

Implementing TPM practices during installation and commissioning phase is crucial for long-term performance and reliability. 1. Initial Cleaning and Inspection: Ensure equipment is clean and defect-free before installation. 2. Training: Provide comprehensive training for operators and maintenance staff, along with detailed documentation. 3. Set Baselines: Establish initial performance metrics and maintenance schedules. 4. Early Management: Involve proactive equipment management from the start. 5. Safety: Prioritize safety measures and protocols to prevent accidents and ensure smooth operation. 6. CMMS: Integrate a CMMS to track equipment history, maintenance activities, and performance data from day one.

Extremely important to understand the design principles to begin with to put in place the SOPs and SMPs. But all procedures in place again do not guarantee the same level of performance principally because of different set of people operating the equipment and more importantly under different set of operating environment in X, Y and Z axes. I mean the efficiency of the preceding and succeeding equipments, the operating platform, maintenance standards of those equipments are going to be different and thus rendering different reliability levels. This forms the basis of RCM that works on the principles of MTBF & MTTR. Thus important to know the online & offline checks required and run to failure concepts on POKA YOKE principles

In my experience, creating a subset of the maintenance plan for operators is of huge importance at this stage. This so-called self-autonomous maintenance plan will be posted at the job station and list the tasks (checks, lubrication etc), frequency, spare parts (for example the oil type) and visuals (pictures) that will answer any questions the operators might have when completing the plan.

Implementing TPM in the operation and improvement phase enhances performance & reliability. 1. Autonomous Maintenance: Empower operators to perform routine maintenance & inspections 2. Focused Improvement: Identify & fix chronic losses through cross-functional team efforts 3. Quality Maintenance: Ensure equipment consistently produces high-quality outputs 4. Planned Maintenance: Schedule regular maintenance activities to prevent unexpected breakdowns 5. Education and Training: Continuously train staff to enhance skills & knowledge 6. CMMS Utilization: Leverage CMMS to monitor equipment performance, track maintenance tasks & analyze data for informed decision-making 7. OEE: Regularly measure OEE to identify & address performance gaps

During my TPM Consultancy engagements I frequently see the focus on Equipment Life Cycle is diminishing. Thus losing out opportunities on designing equipment which are highly energy efficient, inherently safe, easy to operate, maintain and finally environment friendly to dispose. The principles of Early Management if leveraged properly during the Equipment Life Cycle stages will help the Industry to be Safer, Efficient and Sustainable. In built poka-yoke for Safe and easy operation and maintenance. Modular maintenance-free design which is also easy to dispose Easily accessible instrumentation and Controls for measurement inspections, adjustments and maintenance. Thus managing annual shutdown also becomes effective and efficient.

Consider these key aspects also, for a holistic approach to achieve Operational Excellence 1. Leadership Commitment: Ensure senior management's active support and involvement 2. Employee Engagement: Foster a culture where all employees contribute to maintenance and improvement activities 3. Root Cause Analysis: Use tools like the 5 Whys and Fishbone Diagram to identify and address root causes 4. Standardization: Develop and implement SoPs for maintenance tasks 5. Continuous Improvement: Promote a cycle of ongoing improvement through regular reviews & updates 6. Data-Driven Decisions: Leverage CMMS for data analysis, guiding informed decision-making 7. OEE Focus: Regularly measure and optimize Overall Equipment Effectiveness

One of the pillars of TPM, "Initial Control" focuses on applying learning to the new equipment. Once equipment is procured with the new standards, the balance Life cycle is taken care by other pillars of TPM