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What are the most effective ways to implement a total productive maintenance system?

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Total productive maintenance (TPM) is a lean manufacturing tool that aims to improve the reliability and efficiency of machines and equipment by involving all employees in preventive and corrective actions. TPM can reduce downtime, waste, defects, and costs, while increasing productivity, quality, and customer satisfaction. However, implementing TPM is not a one-time project, but a continuous process that requires commitment, planning, and improvement. Here are some of the most effective ways to implement a TPM system in your manufacturing facility.

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1 Assess your current situation

Before you start implementing TPM, you need to understand the current state of your machines and equipment, as well as the maintenance practices and culture in your organization. You can use tools such as the overall equipment effectiveness (OEE) metric, the six big losses framework, and the 5S method to measure and analyze the performance, availability, and quality of your assets. You also need to identify the root causes of any problems or inefficiencies, and the potential benefits and risks of implementing TPM.

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Ramesh Devadig, Ph.D, PMP

Formulation Scale up Scientist | Technical Lead | Product Development Specialist | Project Manager | Lab Management
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In my experience, successful implementation of a TPM system depends on a thorough assessment of existing machinery, maintenance practices, and organizational culture. Leveraging tools like Overall Equipment Effectiveness (OEE), the Six Big Losses framework, and the 5S method allows for precise measurement and analysis of asset performance, availability, and quality. It's critical to pinpoint root causes of inefficiencies and evaluate potential benefits and risks before proceeding with TPM initiatives. Simplifying KPIs is important to ensure clarity and ease of understanding among process stakeholders, enabling accurate periodic assessments of production maintenance facility's current state.

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Prof. Fernando Gon?alves

Black Belt/Melhoria Continua/Lean Six Sigma.
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Aqui est?o algumas etapas eficazes para implementar um sistema TPM: 1. Compromisso da Alta Dire??o: A alta dire??o deve estar comprometida com a implementa??o do TPM e fornecer os recursos necessários. 2. Educa??o e Treinamento: Todos os funcionários devem receber treinamento sobre os princípios e práticas do TPM. 3. Estabelecer Metas Claras: Defina metas claras como reduzir o tempo de inatividade do equipamento ou melhorar a qualidade do produto. 4. Implementa??o Gradual: Comece implementando o TPM em uma área ou linha de produ??o. 5. Manuten??o Aut?noma: Treine os operadores para realizar tarefas básicas de manuten??o. 6. Manuten??o Planejada: Desenvolva um cronograma de manuten??o preventiva.

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2 Set your goals and strategy

Based on your assessment, you need to define your goals and strategy for implementing TPM. You should align your goals with your business objectives and customer needs, and make them SMART (specific, measurable, achievable, relevant, and time-bound). You should also develop a strategy that outlines the steps, roles, responsibilities, resources, and timelines for achieving your goals. You can use tools such as the PDCA (plan-do-check-act) cycle, the A3 report, and the TPM pillar structure to plan and execute your strategy.

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Ramesh Devadig, Ph.D, PMP

Formulation Scale up Scientist | Technical Lead | Product Development Specialist | Project Manager | Lab Management
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In my experience, implementing a TPM system requires defining SMART goals aligned with Critical-to-Quality (CTQ) factors, reflecting both organizational objectives and customer needs. Crafting a strategy utilizing tools such as the PDCA cycle, A3 report, and TPM pillar structure ensures clarity in steps, roles, responsibilities, and timelines. Aligning with organizational goals for quality and operational excellence across departments is paramount, integrating key metrics, KPIs, and associated rewards and promotions to consistently meet CTQ requirements and drive production efficiency. This comprehensive approach emphasizes seamless TPM integration, optimizing effectiveness and long-term sustainability.

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3 Train and empower your employees

One of the key principles of TPM is to involve all employees in the maintenance activities, from operators to managers. This means that you need to train and empower your employees to perform basic maintenance tasks, such as cleaning, inspecting, lubricating, and adjusting the machines and equipment. You also need to encourage them to report and solve any problems or abnormalities, and to suggest and implement improvements. You can use tools such as the skill matrix, the one-point lesson, and the kaizen event to train and empower your employees.

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Akash Sahadevan

Project Coordinator | Inside Sales | Instrumentation | Technical Proposal | Bidding |
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When putting a maintenance schedule together, it’s important to note your team’s skillset and availability to ensure you’re assigning the right staff to the task.

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4 Implement preventive and predictive maintenance

Another key principle of TPM is to prevent or minimize breakdowns, failures, and defects by performing regular maintenance on the machines and equipment. This includes preventive maintenance, which is planned and scheduled based on time or usage intervals, and predictive maintenance, which is based on real-time data and indicators of the condition and performance of the assets. You can use tools such as the maintenance checklist, the failure mode and effects analysis (FMEA), and the condition monitoring system to implement preventive and predictive maintenance.

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5 Standardize and document your processes

To ensure consistency and quality in your TPM activities, you need to standardize and document your processes. This means that you need to establish clear and detailed procedures, instructions, and guidelines for performing the maintenance tasks, as well as for recording and reporting the results and outcomes. You also need to ensure that your processes are aligned with the best practices and standards in your industry and comply with the safety and environmental regulations. You can use tools such as the standard operating procedure (SOP), the work instruction, and the visual management system to standardize and document your processes.

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6 Monitor and improve your results

To measure and evaluate the effectiveness of your TPM system, you need to monitor and improve your results. This means that you need to collect and analyze data and feedback on the performance, availability, and quality of your machines and equipment, as well as on the satisfaction and engagement of your employees and customers. You also need to identify and implement opportunities for improvement, and to recognize and reward the achievements and contributions of your employees. You can use tools such as the performance dashboard, the gemba walk, and the recognition program to monitor and improve your results.

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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?

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Akash Sahadevan

Project Coordinator | Inside Sales | Instrumentation | Technical Proposal | Bidding |
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Regular maintenance also reduces utility bills as machines consume significantly less energy as they perform at higher efficiency levels.

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Vineet T.

Manager Production
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Other than all documental suggestions of TPM To ensure thorough sight clearance & cleaniless of running machinery & plateforms Try to reduce sound levels Sort problems & perfectly predict potential losses Make equipment wise history cards .Mention each & every problem & solution . Hard analysis of each fault or problem

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Abdeslam B.

Lead Auditor IFSV08 & BRCV09 / Consultant senior en FOOD SAFETY et EXCELLENCE OPERATIONNELLE/ Lean Six Sigma specialist
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Un planning de maintenance préventive bien établit permettra de réduire le co?t de la maintenance préventive. Ceci dit, la migration vers un système de maintenance conditionnelle permettra d'améliorer encore le co?t global de maintenance dans une entreprise. Au cours du process de mise en place de la TPM, il faut pouvoir étudier toute la documentation des équipements et commencer par mettre en place des indices sur le bon fonctionnement des appareils à surveiller et qui vont indiquer les bons moments de réaliser des actions préventives au lieu de se contenter d'un programme figée

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What are the most effective ways to implement a total productive maintenance system?

1

2

3

4

5

6

7

1 Assess your current situation

2 Set your goals and strategy

3 Train and empower your employees

4 Implement preventive and predictive maintenance

5 Standardize and document your processes

6 Monitor and improve your results

7 Here’s what else to consider

Manufacturing

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What are the most effective ways to implement a total productive maintenance system?

1

2

3

4

5

6

7

1 Assess your current situation

2 Set your goals and strategy

3 Train and empower your employees

4 Implement preventive and predictive maintenance

5 Standardize and document your processes

6 Monitor and improve your results

7 Here’s what else to consider

Manufacturing

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