Bhushan Barakale

TPM - Total Productive Maintenance TPM focuses on total productivity of equipment throughout its life cycle. It is aimed at increasing machine & process reliability to support lean production. It targets total efficiency, 100% operational availability with respect to delivery, quality, safety & cost with the help of continuous improvement & lean tools such as 5S, JIT, etc. It means total involvement of everyone in the process such as not only maintenance staff but production operators & quality staff as well. The following are considered the TPM pillars which are mainly focused on proactive & preventive techniques for ensuring 100% operational availability. · Autonomous maintenance: It gives operators ownership of their equipment; they are responsible for cleaning, lubrication & inspection of equipment. It helps to identify issues before it’s too late, such as machine breakdown. · Planned maintenance: It includes implementation of preventive and/or scheduled maintenance. It reduces machine breakdowns and unwanted stoppages. Also helps to reduce WIP inventory by improving machine/process reliability. · Quality maintenance: It involves integrating quality staff as well in the process for implementing continuous improvement activities to address recurring quality issues thus reducing the defects/scrap. · Focused improvement: It means improving equipment operation with the help of continuous improvement activities & tools used by proactive cross-functional teams. · Early equipment management: It means production, maintenance, engineering, quality everyone’s input & involvement in design/development of new machine or modification of a machine. It ensures quick operational readiness & reduce or eliminate failure, scrap & issues with installations/modifications. · HSE: Health, Safety & Environment ensures safe & healthy practices are being followed throughout the process which also meets environmental standards & regulations. It helps to provide a safe workplace for employees, promote sustainability & earn customer trust. · TPM in admin: It includes implementation of TPM across all functions such as sales, supply chain & logistics, customer service, HR & finance to increase efficiency, increase profits and customer satisfaction by reducing delays & improved quality. · Training & education: It involves training all employees to fill the skill gap. It can motivate & engage employees thus increasing employee satisfaction. It helps employees to do their jobs safer & efficient way and support TPM principles. TQM – Total Quality Management & TPM TPM focuses on operational availability/equipment efficiency, whereas TQM has a broader focus and it’s involved with customer satisfaction by improving the quality of product or service. TPM is a Part of TQM. TQM involves employees, management, everyone at all levels within the organization.