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How can TPM improve lean manufacturing for your facility?

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Lean manufacturing is a philosophy and a set of practices that aim to eliminate waste, improve quality, and increase customer value. However, lean manufacturing alone is not enough to ensure optimal performance and efficiency. You also need to maintain and optimize your equipment, processes, and people. That's where TPM, or total productive maintenance, comes in.

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Pablo Mellicovsky

Founder & Business Manager at INDX | Architect Industry 4.0 Solutions | Industrial Engineer | Speaker
Jon Elejabarrieta Anza

Production and Continuous Improvement Manager at Ormazabal
Er. Ram Teja Ganta

Senior QA/QC (Mech) Professional > Manufacturing | Metal Fabrication | Machinery | Farm Equipment | Energy

1 What is TPM?

TPM is a holistic approach to equipment management that involves everyone in the organization, from operators to managers. TPM focuses on preventing breakdowns, defects, and accidents by ensuring that machines are always in good condition and ready to use. TPM also empowers workers to take ownership of their equipment and participate in improvement activities. TPM has eight pillars that cover different aspects of equipment management, such as autonomous maintenance, planned maintenance, quality maintenance, and focused improvement.

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Er. Ram Teja Ganta

Senior QA/QC (Mech) Professional > Manufacturing | Metal Fabrication | Machinery | Farm Equipment | Energy
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Total Productive Maintenance (TPM) is the process of maximizing equipment effectiveness through the active involvement of all supporting departments. TPM is the process of using machines, equipment, employees and supporting processes to maintain and improve the integrity of production and the quality of systems. TPM strives for perfect production. That is: - No breakdowns - No stops/Slow - No defects - No accidents

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2 How does TPM support lean manufacturing?

TPM supports lean manufacturing by reducing waste, increasing quality, and enhancing customer value. By preventing breakdowns, TPM reduces downtime, inventory, and rework. By preventing defects, TPM improves quality, customer satisfaction, and profitability. By involving everyone in improvement, TPM fosters a culture of continuous learning, innovation, and teamwork. TPM also helps to optimize the flow of materials, information, and energy through the production system, which is a key principle of lean manufacturing.

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3 How to implement TPM in your facility?

Implementing TPM in your facility requires a clear vision, strong leadership, and a systematic plan. To begin your TPM journey, assess your current situation and identify your goals and gaps using tools such as the TPM audit or the overall equipment effectiveness (OEE) metric. Then, create a cross-functional TPM team with assigned roles and responsibilities, as well as the necessary skills and resources. Select a pilot area or machine to test the benefits of TPM and apply the eight pillars of TPM. Afterward, scale up and standardize the TPM practices across your facility, refining and improving your methods and procedures based on lessons learned from the pilot area or machine. Don't forget to communicate and celebrate your achievements and challenges. Finally, sustain and improve your TPM performance by conducting regular audits and reviews, encouraging employee participation, rewarding recognition, seeking external benchmarking, and obtaining certification to validate excellence.

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Pablo Mellicovsky

Founder & Business Manager at INDX | Architect Industry 4.0 Solutions | Industrial Engineer | Speaker
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La implementación de un sistema MES para medir el OEE puede complementar y fortalecer la aplicación de la filosofía TPM al proporcionar datos en tiempo real, identificar problemas y áreas de mejora, y facilitar la programación de actividades de mantenimiento preventivo. Esto permite una gestión más efectiva de los activos de producción y contribuye a la optimización del rendimiento y la eficiencia operativa en el marco de la TPM.

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Jon Elejabarrieta Anza

Production and Continuous Improvement Manager at Ormazabal
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En primer lugar se debe generar un cambio cultural en la empresa hacia la mejora continua. Es necesario involucrar a las diferentes áreas que componen la cadena de valor de una empresa en la mejora continua. Para ello sería interesante crear espacios de trabajo comunes en los que se compartan los KPI definidos por las estrategias competitivas de la empresa. Estos indicadores serán la base y el punto de partida para llevar a cabo proyectos que tengan como objetivo el optimizar los recursos productivos, mejora de la calidad y en definitiva conseguir unos mejores resultados económicos.

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Er. Ram Teja Ganta

Senior QA/QC (Mech) Professional > Manufacturing | Metal Fabrication | Machinery | Farm Equipment | Energy
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This is generally done in 5 steps: identifying a pilot area, restoring equipment to prime operating condition, measuring OEE, addressing and reducing major losses, and implementing planned maintenance.

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Joaozito José dos Santos

ELETRICISTA
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Trata de processo que visa viabilizar , melhores resultados de produtividade, com a garantir menas vezes paradas indesejadas, impactando diretamente no custo do produto final. Cabe salientar que para obter estes melhores resultados com o processo de TPM , é vital o treinamento da equipe de manuten??o e de planejamento do processo

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4 What are the benefits of TPM for your facility?

TPM can bring many benefits to your facility, such as increased productivity and efficiency, improved quality and reliability, enhanced safety and morale, reduced costs and waste, and higher customer satisfaction and loyalty. TPM can help you reduce downtime, increase output, optimize resources, eliminate defects, ensure consistency, meet customer expectations, prevent accidents, injuries, and illnesses, create a positive work environment for employees, save money, materials, and energy by minimizing losses and maximizing value, and deliver high-quality products and services that meet or exceed customer needs and preferences.

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Er. Ram Teja Ganta

Senior QA/QC (Mech) Professional > Manufacturing | Metal Fabrication | Machinery | Farm Equipment | Energy
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Implementing TPM can shows advantages for organizations, including: - Reduced Equipment Failure and Downtime: Minimizing unexpected breakdowns and disruptions. - Extended Equipment Lifespan: Prolonging the productive life of machinery. - Enhanced Workplace Safety: Ensuring a safer work environment for all personnel. - Lower Maintenance Costs: Reducing expenses associated with reactive repairs. - Increased Productivity: Optimizing equipment performance for higher output.

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Dimas Campos de Aguiar

Black Belt | Engineering PhD | FMEA Moderator
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TPM focuses on early equipment management, preventing breakdowns, and reducing equipment downtime. TPM involves training operators to conduct simple maintenance tasks, empowering them to take ownership of their equipment and environment. This can lead to increased engagement and a sense of responsibility among employees. By addressing equipment issues promptly and conducting regular maintenance, TPM helps in reducing defects, breakdowns, and other sources of waste in the manufacturing process. Preventative maintenance and a focus on equipment reliability can result in better product quality and consistency, which aligns with lean manufacturing principles.

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5 What are the challenges of TPM for your facility?

TPM is not a quick fix or a one-time project, but rather a long-term commitment and cultural change that requires dedication, collaboration, and adaptation. The challenges of implementing TPM in your facility include resistance to change from employees, lack of resources, and complexity and variability. To overcome these obstacles, it is important to communicate the benefits and expectations of TPM clearly and frequently, allocate and prioritize resources wisely, simplify and standardize operations, and adapt TPM practices according to your specific situation.

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Dimas Campos de Aguiar

Black Belt | Engineering PhD | FMEA Moderator
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It is a cultural change. Shifting to a TPM mindset requires a cultural shift where employees are actively engaged in maintenance and improvement activities. Getting buy-in from all levels of the organization and fostering a culture of continuous improvement is a real challenge. Providing adequate training and developing the necessary skills for operators to perform maintenance tasks can be time-consuming and require investment in resources. Moreover, there is a natural Resistance to Change, where Employees may resist the changes that come with TPM, especially if they are accustomed to traditional maintenance practices. Overcoming resistance and garnering support for TPM initiatives can be challenging.

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6 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?

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Pablo Mellicovsky

Founder & Business Manager at INDX | Architect Industry 4.0 Solutions | Industrial Engineer | Speaker
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Monitoreo en tiempo real: Un sistema MES recopila datos (OEE), como tiempo de operación y tiempos de inactividad, en tiempo real, facilitando el seguimiento continuo del tiempo de actividad, esencial para la TPM. Identificación de problemas: El análisis de datos del MES revela patrones de tiempo de inactividad y pérdidas de eficiencia, lo que ayuda a identificar áreas que necesitan mejoras bajo la TPM, como mantenimiento preventivo y reducción de pérdidas. Programación eficiente de mantenimiento: Con la información del MES, se pueden programar actividades de mantenimiento preventivo y basado en datos, reduciendo el tiempo de inactividad no planificado y mejorando la fiabilidad de los equipos, objetivos clave de la TPM.

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How can TPM improve lean manufacturing for your facility?

1

2

3

4

5

6

1 What is TPM?

2 How does TPM support lean manufacturing?

3 How to implement TPM in your facility?

4 What are the benefits of TPM for your facility?

5 What are the challenges of TPM for your facility?

6 Here’s what else to consider

Manufacturing

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How can TPM improve lean manufacturing for your facility?

1

2

3

4

5

6

1 What is TPM?

2 How does TPM support lean manufacturing?

3 How to implement TPM in your facility?

4 What are the benefits of TPM for your facility?

5 What are the challenges of TPM for your facility?

6 Here’s what else to consider

Manufacturing

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