Total Productive Maintenance
Total Productive Maintenance (TPM) is a tool that ensures timely and cost-effective equipment repair. It can be used in all businesses, including offices, but is particularly useful in the manufacturing sector. TPM was first introduced by American consultants in Japan and is an offshoot of TQM1 The Japanese adopted and developed the concept and began teaching the TPM in other countries including the U.S. in the 1970sTPM has since then developed into a valuable tool for effective planned maintenance, reducing down time, and saving of time, energy and money.The success of a TPM program depends on commitment by the top management and a total team eff
Each piece of equipment is carefully studied for downtime, productive time, and availability. For example, equipment such as personal computers are categorized as least critical since they do not require significant maintenance and are easily replaced. ortThe goal is to increase production by flawless operation and eliminating downtimeTPM trains employees to plan and complete scheduled maintenance and to optimize equipment performance. The key to implementing TPM is to classify each piece of equipment according to its criticality and to focus maintenance efforts on the most critical category. Tracking overall equipment effectiveness is also part of TPM. Meticulous record is kept of all operations, inspections, and maintenance actions. These steps have transformed maintenance practices from being essentially "reactive" in nature to a "predictive" state. Equipment is then modified and processes improved to minimize downtime and failures. Trouble-free operation of equipment is doubly critical at UTC because breakdown of testing equipment not only affects runtime but can also damage the product being tested; hence the importance of TPM. Employees are trained to identify problem areas that affect productivity. The Facilities group is constantly engaged in progressively integrating all its systems and forward monitoring of system health as part of its TPM program. Visual controls, such as easy-to understand labels, are part of proper TPM. Relentless Root Cause Analysis and use of Quality Clinic Process Charts enables the maintenance teams to prioritize maintenance and tackle the root causes of equipment trouble. Planned and major maintenance is carried out by specialized maintenance personnel.
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