Total Productive Maintenance (TPM), a production maintenance system that can increase productivity
The development of a developed manufacturing industry requires companies to always meet consumer needs and increase profits. Well, total productive maintenance is one method that can be done to fulfill this.
Caring for all facilities and equipment is needed to be able to create a productive work environment and be able maintain quality and able to achieve company goals quickly. Damage to tools or machines can threaten the safety of each employee and cause large financial losses.
So, what is the total productive maintenance? What are the goals and stages and apply them? Find the answer to the article Total Productive Maintenance below.
Understanding Total Productive Maintenance
TPM or Total Productive Maintenance is one system that can be used to maintain and also improve the quality of production through equipment care activities and also work equipment such as machines, equipment, and various other work equipment.
The main focus of total productive maintenance is to ensure that all equipment and production equipment can operate in good conditions to avoid damage and also delays in the production process.
Total Productive Maintenance is an innovative concept from Japan that begins with the implementation of preventive maintenance in 1951. The concept was adopted from the United States. The first company to introduce this concept is Nippondenso which is a Toyota supplier in 1960 with the slogan “Productivity Maintenance with Total Employee Participation.”
Seiichi Nakajima, who at the time served as Vice Chairman JIPM (Japan Institute of Plant Maintenance) was later known as a TPM father.
The purpose of the implementation of Total Productive Maintenance (TPM)
The main objective of the implementation of total productive maintenance is to increase productivity on various production equipment and equipment with treatment investments that are needed. So, being able to prevent six large losses that include breakdown, setup and adjustments, small stops, slow running, startup defects, and production defects.
Stages of Application of Total Productive Maintenance (TPM)
Some stages that must be taken to apply TPM in a company are as follows:
- Conduct an initial evaluation at the current TPM level
- Introducing the TPM method to the team
- Make a special TPM committee
- Establish policies, goals, and also TPM targets
- Arrange the Master Plan to be able to develop TPM
- Make TPM training for all employees and parties that have interests.
- Apply various preparation processes.
- Doing all programs and TPM policies so that they can achieve goals and also targets for productive maintenance that has previously been established.
The company’s management has a very important role in implementing total productive maintenance. Without the strong support and committee of the management, as well as the collaboration of all company employees, the objectives and the target program will be difficult to achieve.
Cause of the failure of TPM.
Applying a total productive maintenance strategy does need a lot of change, and all adjustments in it will make the company scramble to obtain the momentum around their project.
There are at least four main things that implement total productive maintenance failed, namely:
1. Cultural change
Adjusting the previous organizational culture based on the principle of total productive maintenance may sound like an abstract and wide concept. However, this involves various practical tactics which can then be followed up by companies that can move to achieve their success.
For this reason, Reliable Plant explained that some important considerations must be done, namely:
- Establish a formal code of ethics that can determine the relevant expectations of how employees are expected to interact.
- Getting support from management at the beginning of the transition and ensuring the leaders can support each other.
- Make care strategies on equipment that are still new to avoid the tool falling in the reactive pattern that can damage the total production maintenance plan.
- Increase expectations to be able to carry out maintenance of tools preventively and predictively.
This specific strategy can be added to be able to create dramatic cultural changes that can revitalize the maintenance department. For most companies, the tendency to assume the maintenance team as an absorbent cost is very necessary, so as not to cause a significant gap between the maintenance team and other teams.
Later, directly this can trigger an environment where employees in the maintenance can work more actively according to the call.
Hearing the culture is very important for the success of total productive maintenance. Reliable Plant Inside can show that treating maintenance as a major business contributor is the right step to total productive maintenance success.
2. Rejection of change
A company is equal to living organisms, some of the characteristics will always be a tendency to reject as a form of self-defense so that it can continue to live. This is a natural reaction because not everything can change smoothly in seconds.
There are two reasons for changing refusal when applying total productive maintenance, namely:
- Total Productive Maintenance demanded a significant change in the company’s workflow
- Total productive maintenance implies a sustainable increase, which means there are several revisions of one particular workflow.
There are two ways to deal with it.
First, the actual introduced change is reducing the workload of the employee as a whole. Total productive maintenance will make work done so far by employees become easier and also more efficient. Make sure they know this so that they are more motivated to do their best.
Second, motivate employees by offering something like a gift. You need a working mechanism that can ensure happy employees with new conditions, and their best performance needs to be appreciated. When they see and certain rewards, then they will work well.
3. Inventory waste
The warehousing strategy and the implementation of inventory management traditionally often separate parts and also inventory of production areas and allows significant overhead inventory to be able to avoid deficiencies of specific parts or equipment.
This strategy can directly weaken the operational strategy of Lean, including the total productive maintenance. A study published International Journal of Advanced Engineering Technology said that excessive inventory would cause waste.
Well, by setting the Equipment Effectiveness Management strategy, it will enable the manufacturer to:
- Measure what resources are needed by various assets
- Identify the best location to be able to save components and inventory so that it is not intrusive but easily accessible by the maintenance team and also the production team.
- Apply a more constant flow of material to streamline the operation.
The article explains that the reduction of excess inventory and storing several materials near the production line can make it easier to apply the Total Productive Maintenance function and simplify the equipment management process.
Modern computerized maintenance management systems are very important when you consider implementing strategic inventory management strategies.
The system will allow each user to record use as part of the accompanying application, and easily see the level of inventory in several locations and receive warnings when supplies must be refilled.
4. Lack of support from Top Management
You cannot apply Total Productive Maintenance without the support of managers. The top management must be able to be used as a driving force behind every change and lead the company by giving a good example.
You also have to make sure every rank of Puncak Management realizes how to apply the planned changes. You must encourage them to plan change and also have a strategic vision of implementation based on these changes.
That is why every stakeholder has an important role in making plans and cooperating with everyone who has a complete understanding of the production process.
Thus the complete explanation of us about total productive maintenance. So, total productive maintenance is one system that can be used to maintain and also improve the quality of production through equipment care activities and also work equipment such as machinery, equipment, and various other work equipment.
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