The TPM concept was developed in Japan in the late 60s and early 70s at Nippon Dansau, an electrical equipment supplier for Toyota Corporation. The well-known statement of the founder of Toyota “The forces do not come through curing processes, but due to preventive maintenance of equipment.”
TPM means loosely translated “universal effective maintenance”. In this case, the “universal” refers to the entire system of effective care for the equipment during the entire service life. It also refers to the inclusion of each employee in the process through the involvement of individual operators for maintenance. Moreover, the application of TPM requires certain obligations from the management of the enterprise.
The challenges that TPM solves:
- installation and commissioning
- idle and small stops
- speed loss
- marriage and alteration
- starting losses
The system of universal care for equipment is not about the problem of equipment malfunction, but the understanding of the maintenance of the means of production as an integration of the operation and maintenance processes. As well as the early involvement of maintenance personnel in the development of maintenance schedules and accurate accounting of equipment condition. TPM plays an important role in production management in the “just in time” system. The presence of interference leads to a loss of time, which increases throughout the value chain.
The rationale for the inclusion of universal care equipment in the philosophy of lean manufacturing (Lean manufacturing, TPS) is presented in the diagram.
Eight principles of TRM:
- Continuous improvement
- Offline maintenance
- Maintenance planning
- Training and education: improving the skills of staff in operation and maintenance of equipment.
- Launch control
- Quality management
- TPM in administrative areas: losses and waste are eliminated in indirect production units.
- Labor safety, environment and health
Offline maintenance is the most important principle of TPM. Its goal is to minimize the efficiency losses that occur due to device failures, short stops, rejects, etc. For this, an increasing part of the necessary maintenance activities (cleaning, lubrication, technical inspection of devices) is simplified, standardized and gradually transferred to the field. in duties of employees. As a result, employees of the chief mechanic department are exempt from current routine activities, so they get more time to develop and implement improvement measures.
The concept of Total Productive Maintenance is the basis for the success of manufacturing companies.
Universal care equipment squeezes the maximum performance of the machines during normal operation and maintaining performance for a long time. Perfectly working equipment, which is repaired before it breaks, saves time, reduces costs and motivates workers.
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