Total productive maintenance: tips to boost efficiency
Ready to amp up your productivity? This article will guide you in implementing total productive maintenance (TPM), helping you to minimize downtime, maximize output, and exceed your performance goals.
7 min read
Much like the vibrant colors of a rainbow and the enchanting notes in an octave, number seven also holds great significance in the manufacturing world.
With its seven pillars, Total Productive Maintenance (TPM) allows manufacturers to tap into the full potential of their production processes and optimize their operations across all seven days of the week. Through its holistic approach, TPM encourages everyone in the organization to take ownership and responsibility for equipment reliability and performance. Like the seven chakras of spirituality, TPM and its pillars take care of every aspect of manufacturing, leaving you totally zen to enjoy the results.
Whether you’re a seasoned manufacturer seeking to optimize your operations or a curious mind eager to explore the maximum levels of efficiency, this article will explore TPM and the magic of seven.
What is TPM in manufacturing?
Total productive maintenance is a systematic way of managing machines and equipment to improve their performance and lifespan. It focuses on preventing breakdowns and maximizing the efficiency of the equipment we use.
Think of TPM as taking care of a car. Regular oil changes, tire rotations, and inspections keep the vehicle running and help prevent any major problems. TPM does something similar for machines and equipment in factories or businesses.
In TPM, everyone who works with the machines gets involved in their upkeep.
It’s not just the maintenance crew’s responsibility but a team effort. Operators and managers learn how to perform routine maintenance tasks and keep an eye out for potential issues. By catching small problems early on and fixing them, you can avoid costly repairs and keep the machines running at their best.
TPM is all about being proactive.
Instead of waiting for something to break down, it’s best to take steps to prevent it from happening. This saves time and money while helping businesses run more smoothly. Giving the machines regular check-ups helps keep them in top shape and ensures you can keep up with the demands of production.
What are the benefits of TPM?
TPM provides a holistic approach to maintenance and operations management, offering many benefits to organizations that implement and embrace its principles.
Some key benefits of TPM are as follows.
Increased equipment reliability
TPM focuses on proactive maintenance and equipment care, resulting in improved equipment reliability. By addressing potential issues and performing regular maintenance activities, organizations can reduce breakdowns, unplanned downtime, and disruptions in production.
Better equipment availability
TPM aims to maximize equipment availability for production by minimizing breakdowns and reducing setup times. This leads to increased effectiveness and allows organizations to meet production targets consistently.
Higher product quality
TPM focuses on quality maintenance, ensuring that equipment is in optimal condition to produce high-quality products. By preventing defects and errors, TPM helps to improve product quality and customer satisfaction.
Improved Overall Equipment Effectiveness (OEE)
OEE is a metric that measures the utilization and performance of equipment. Through different TPM methods, organizations can enhance OEE by reducing downtime, improving cycle times, and optimizing equipment efficiency.
TPM encourages operator involvement and empowerment through autonomous maintenance and training programs. This leads to a sense of ownership and responsibility among employees, fostering a culture of learning and teamwork.
TPM helps reduce maintenance costs by focusing on preventive and predictive practices. It minimizes the need for costly repairs, emergency maintenance, and equipment replacement due to premature failures. Additionally, improved equipment efficiency reduces downtime, contributing to cost savings and increased profitability.
Safer workplace environment
Safety is an inherent part of TPM in manufacturing. Promoting regular equipment inspections, maintenance, and employee training helps identify and address potential safety hazards. It also creates a safer and healthier workplace environment for employees.
Continuous improvement culture
TPM fosters a culture of continuous improvement by engaging employees in problem-solving activities, encouraging innovative ideas, and promoting an ongoing learning and development mindset.
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What are the 7 pillars of TPM?
The TPM philosophy consists of seven pillars aiming to maximize the efficiency and effectiveness of equipment and processes.
The pillars of manufacturing TPM are as follows.
Empower operators to take responsibility for routine maintenance tasks, including cleaning, inspection, and minor repairs. It promotes a proactive approach to equipment maintenance and encourages a sense of ownership among operators.
Planned and scheduled maintenance activities focus on preventing equipment failures and unplanned downtime. It involves creating inspection plans, conducting preventive maintenance, and regularly monitoring equipment conditions.
Identifying and eliminating losses, inefficiencies, and waste in production processes encourages continuous improvement. This pillar emphasizes problem-solving, root cause analysis, and implementing innovative ideas.
Early equipment management
Involves considering equipment reliability and maintainability during the design and acquisition phase. It focuses on improving equipment effectiveness, reducing life cycle costs, and ensuring ease of maintenance.
Prevent defects, errors, and quality issues in the production process with a thorough inspection, quality control, and proactive measures to maintain and improve product quality.
Education and training
Recognizes the importance of providing ongoing education and training to employees at all levels. It includes technical training, skill development, and knowledge sharing to enhance competence and promote a culture of continuous learning.
Extends the TPM principles beyond the production floor and into administrative and support functions. It focuses on optimizing administrative processes, reducing waste, improving workflow, and enhancing overall office efficiency.
There’s also an unofficial eighth pillar known as Safety, Health, and Environment (SHE). This aspect focuses on a safe and healthy work environment, adhering to safety protocols, and minimizing the environmental impact of operations.
How to implement TPM?
Implementing a TPM system involves several steps and requires a systematic approach.
Here’s a general outline of how to implement TPM.
1. Establish a TPM team
Form a team of representatives from various departments, including production, maintenance, engineering, quality, and management. This team will lead and drive the TPM implementation process.
2. Conduct an initial assessment
Evaluate the current state of maintenance practices and equipment performance. Identify areas that need improvement and prioritize them based on their impact on productivity, reliability, and business goals.
3. Set TPM goals and objectives
Define specific and measurable goals for TPM implementation. Some examples could be:
Reducing equipment downtime
Increasing maintenance efficiency
Enhancing employee skills and involvement
4. Develop a detailed implementation plan
Create a comprehensive plan that outlines the activities, timelines, and responsibilities for TPM implementation. This should include initiatives such as:
Education and training programs
5. Implement autonomous maintenance
Empower operators to take responsibility for routine maintenance tasks and conduct autonomous maintenance activities, such as cleaning, inspection, and minor repairs. Provide training and guidance to operators to ensure they can perform these tasks effectively.
6. Implement planned maintenance
Develop a maintenance schedule based on equipment conditions and historical data. Implement predictive maintenance strategies to prevent failures and extend equipment life. Set up a system for tracking maintenance activities and monitoring key performance indicators.
7. Continuous improvement
Nurture a culture of continuous improvement by encouraging employees to identify and address equipment-related issues and inefficiencies. Implement improvement projects and encourage employees to be more involved through suggestion systems, team meetings, and training programs.
The implementation may require additional steps or customization depending on your business, industry, and goals. It’s crucial to configure TPM according to your business needs and to keep adjusting it as you progress.
Katana and TPM in manufacturing
As with many aspects of manufacturing, there are systems and online platforms to optimize tasks and operations. Many businesses opt for ERP or cloud solutions to take care of mundane daily tasks for them. In the true spirit of TPM, these tools help streamline workflows and minimize the risk of human errors.
Katana is an all-in-one manufacturing platform that can support TPM implementation with its many features.
Production planning and scheduling
Effective manufacturing TPM requires planning and scheduling maintenance activities without disrupting production. Katana’s production planning features enable you to create and manage production orders, allocate resources, and schedule maintenance activities, creating a balance between production output and maintenance efficiency.
Katana’s inventory management capabilities help you maintain optimal stock levels, track spare parts with barcode scanning or serial number tracking, and create reorder points to ensure you have the necessary supplies for maintenance tasks. This will help in reducing downtime and streamlining the maintenance process.
TPM relies on data analysis to identify patterns, monitor performance, and make informed decisions. Katana provides real-time visibility into production and maintenance data, offering analytics and reports that help you gain insights into aspects of your manufacturing, such as:
Other critical metrics
This information empowers you to identify improvement opportunities, prioritize maintenance efforts, and make data-driven decisions for continuous improvement.
Collaboration and communication
A smooth TPM system requires collaboration and communication among different teams and stakeholders. Katana’s Shop Floor App enables seamless communication between departments. It gives you full shop floor control and your operators access to their tasks, fostering a collaborative environment that promotes TPM principles and practices.
Katana offers seamless integrations with various software systems, enabling a streamlined TPM implementation. Connecting to tools that optimize accounting, data analytics, and automation, ensures smoother data flow and enhanced visibility while supporting data-driven decision-making for TPM in manufacturing.
Now, having grasped the essence of TPM, it’s time to unleash its full power and explore the boundless opportunities to perhaps one day expand your business across the seven seas.
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