Wednesday, 19 December 2018

TPM Implementation in Production Line

TPM Implementation. The Lean methodology, but unfortunately most of them forget about the importance of equipment and machine maintenance. In fact, the performance of the machine will largely determine the quality and productivity of a manufacturing process.

The most common case is, maintenance is more reactive. The machine is repair when there is damage, and damage often occurs. A large amount of inventory of spare parts piled up in the warehouse and became obsolete. Often operators ignoring the early signs of potential damage. The operators do not have any competence in the maintenance of the machines they operate on a daily basis.

What if this situation occurs in the aircraft manufacturing industry, for example? In the aircraft industry, very high levels of discipline and standards must be met by all parties involved in production activities; ranging from maintenance, parts suppliers , to material suppliers. Procedures are made very specific, and every step of the process is carefully documented. The expected result is the low number of accidents caused by engine failure will be suppress.

For example

By applying high standards and discipline by aircraft manufacturers in the United States, as many as 27,000 flights in the country each day are spared from accidents caused by engine damage. The same is true in NASCAR Winston Cup Racing. To become a champion, riders are very dependent on engine performance; every race car must meet specified safety standards and engine conditions must always be prime and reliable.

Likewise, organizations that want to win the competition and achieve world class position must be able to implement the Total Productive Maintenance (TPM) program successfully.

TPM, as you already know, is a maintenance maintenance method whose goal is to increase productivity in the production line by improving and maintaining engine performance. One way is to involve operators in machine maintenance; not just rely on maintenance to deal damage (especially minor damage).

To succeed the TPM, the production and maintenance process must go hand in hand. The indication of TPM success is measured by OEE (Overall Equipment Effectiveness).

TPM Leadership

TPM requires leadership effectiveness from the beginning of implementation (hence the tool has the word "Total" in it). Without effective leadership that ensures everyone involved will perform their specific function, machine performance will continue to decline and TPM initiatives will only be short-lived. Many misrepresent TPM as a program to "fix something" instead of preventing machine breakdown.

They see maintenance as a non-value-added process and incur maintenance costs to save. This causes a slowdown in engine performance and makes the engine lose its effectiveness.

12 Steps of TPM Implementation

Successful companies generally have a TPM implementation plan consisting of the following 12 steps:

    • Step 1 - Announcement of the TPM program . Top management must create an environment that will support the running of the TPM program. Without management support, there will be skepticism and resistance that may cripple the initiative.

    • Step 2 - Hold a formal training program . This program will provide information and educate every employee in the company about TPM activities, benefits, and the importance of each person's contribution to succeed. This training can be provided by an internal practitioner (if any) or by an outsource consultant .

    • Step 3 - Create a support organization structure . This team will maintain and ensure TPM run as soon as the program starts. Team-based activities are critical to TPM success. The team generally consists of people from every level of the organization - from management to shop floor. This team will communicate and make sure everyone works for the same purpose.

    • Step 4 - Define the TPM basic rules and quantitative targets . Analyze the current state and set the SMART target: Specific, Measurable, Attainable, Realistic and Time-based.

    • Step 5 - Create a detailed master deployment plan . This plan will identify the resources need. When the training should be held. When restoration and repair of machinery, management system and maintenance technology .

    • Step 6 - Kick-off TPM . Implementation begins at this stage.

    • Step 7 - Improve the effectiveness of any existing machine . The project team will analyze each machine and make necessary improvements.

    • Step 8 - Install an autonomous maintenance program by the operator . Routine cleaning and inspection by the operator will help stabilize engine conditions and prevent damage / degradation of performance.

    • Step 9 - Is there a planned preventive maintenance program . Create a schedule to do maintenance to prevent damage to any existing machines.

    • Step 10 - Provide training to improve maintenance and operational capabilities . The maintenance department can be a resource person and lecturer who provides training, advice, and information about the machine to the team.

    • Step 11 - Develop the early equipment management program . Establish the principles of care for prevention in the design process of machinery.

    • Step 12 - Continuous improvement . As is complete in every Lean initiative, the organization must develop a continuous improvement mindset for it.

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