Recently I was watching a series of video on interesting topic “Ancient Aliens”. Now for sure that has nothing to do with lean manufacturing. I was watching some videos and somehow came through this video series and loved it.
Today we discuss about Total productive maintenance(TPM) as a waste elimination tool.
TPM defined as TPM (Total Productive Maintenance) is a maintenance philosophy designed to integrate equipment maintenance into the manufacturing process.
The goal of any TPM program is to eliminate losses tied to equipment maintenance or, in other words, keep equipment producing only good product, as fast as possible with no unplanned downtime. The unique feature of TPM is Autonomous Maintenance.
Autonomous Maintenance defined as Machine adjustments made by their operators who are deemed to have unique knowledge about the machines. It is a principal component of total productivity maintenance (TPM).
In TPM mainly focus 16 losses and eliminate from the process.16 losses’ are:
A Seven major losses that impede overall equipment efficiency
1 Failure losses (Breakdown)
Losses due to failures. Types of failures include sporadic function-stopping failures, and function-reduction failures in which the function of the equipment drops below
2 Set up and adjustment losses
Stoppage losses that accompany set-up changeovers
3 Cutting blade change losses
Stoppage losses caused by changing the cutting blade due to breakage, or caused by changing the cutting blade when the service life of the grinding stone, cutter or bite has been reached.
4 Start-up losses
When starting production, the losses that arise until equipment start-up, running-in and production processing conditions stabilize.
5 Minor stoppage and idling losses
Losses that occur when the equipment temporarily stops or idles due to sensor actuation or jamming of the work. The equipment will operate normally through simple measures (removal of the work and resetting).
6 Speed losses
Losses due to actual operating speed falling below the designed speed of the equipment.
7 Defect & rework loss
Losses due to defects & reworking.
Losses that impede equipment loading time
8 Shutdown (SD) losses
Losses that arise from planned equipment stoppages at the production planning level in order to perform periodic inspection and statutory inspection.
Five Major losses that impede workers efficiency
9 Management losses
Waiting losses that are caused by management, such as waiting for materials, waiting for a dolly, waiting for tools, waiting for instructions etc.
10 Motion losses
Man-hour losses arising from differences in skills involved in etc.
11 Line organization losses
Idle time losses when waiting for multiple processes or multiple platforms.
12 Distribution losses
Distribution man-hour losses due to transport of materials, products (processed products) and dollies.
13 Measurement and adjustment losses
Work losses from frequent measurement and adjustment in order to prevent the occurrence and outflow of quality defects.
Three major losses that impede efficient use of production subsidiary resources
14 Energy losses
Losses due to ineffective utilization of input energy (electric, gas, fuel oil, etc) in processing.
15 Die, jig and tool losses
Financial losses (expenses incurred in production, regarding renitriding, etc.) which occur with production or repairs of dies, jigs and tolls due to aging beyond services life or breakage.
16 Yield losses
Material losses due to differences in the weight of the input materials and the weight of the quality products.
We have discussed many lean tools in our lean tools series. This post by our guest consultant is about the lean tools in apparel industry. Read On…
“Eight Lean Tools” defined as waste elimination tools. With lean manufacturing we mainly focus on waste. Waste defined as “Anything that adds Cost to the product without adding Value”.
Total productive Maintenance:
“The Combination of Best features between Productive & Predictive Maintenance by innovative Management strategies With total employee Involvement.”
“Through sort, set, shine, standardize and sustain create better workplace organization”.
“The use of controls that enable an individual to immediately recognize the standard and any deviation from it”.
Standardized Work Process:
“It is the current agreed upon best method to complete the work in a process.”
“Team-based improvement activity that significantly reduces setup and changeover time.”
“A signal, usually a card, used to signal the movement or production of materials.”
“The prevention of making errors, which would result in defects and lost time.”
“Using the systematic problem solving tool to sort out problem.”
“Through balance workload among work station creates Continues flow.”
We will discuss each of these tools in detail in the future posts.