TPM: A typical day of a machine with the TPM method

Produce more without extra costs? Choose for the TPM method, Total Productive Maintenance, which improves your machine production time, reduces the downtime and breakdowns and optimizes productivity and quality

La journée d'une machine avec la méthode TPM

The day of a machine with the TPM method, Total Productive Maintenance

Do you want to reduce time and wasted resources? Produce more efficiently and reduce waste at a lower cost?

Choose the TPM method, Total Productive Maintenance, which will improve the productive time of your production equipment by reducing downtime and breakdowns. While optimizing productivity, quality and other performance indicators.

OBJECTIVE ZERO STOP/BREAKDOWN, ZERO FAULTS, ZERO ACCIDENTS

Operation of a machine with the TPM approach

 
 

To be efficient, a site needs a reliable production tool. The TPM approach or Total Productive Maintenance is therefore centred on the machine.

When a company plans to work Just In Time and Zero Stock

It must not forget that it will not be able to meet the deadlines it has announced to its clients if it is not certain that :

The machines and tools will be available during all the operating time

The quantities launched will be obtained (good products)

Planned times are accurate and will be respected

To do this, the company must have eliminated the unexpected and chance in its production activities.
The reliability work is done first and then used to establish self-maintenance programs.

When do we have to use TPM, Total Productive Maintenance?


SESA SYSTEMS cleaning station for example of the TPM method

TPM should be reserved for equipment for which the cost of underperformance is higher than the cost of obtaining performance.

The implementation of the TPM is done in stages following a structured and rigorous methodology. It must start with a PILOTE project. This makes it possible to train the first level management, the sector manager and support functions such as methods and maintenance right from the start. On this basis and as soon as the significant results are obtained, the TPM can begin to be deployed in the rest of the site. So it's a long-term job.

Character SESA SYSTEMS for example of the TPM method

FOLLOW-UP OF A DAY OF PRODUCTION OF A MACHINE

Minimize losses with TPM

 
 

By observing the day of a machine, one realizes that it does not work during all the opening time of the workshop.
There are operations that require shutdown or at least unproductive phases such as series changes, recharging, maintenance, preheating... This introduces the notion of gross running time.
During the gross running time, one would expect a production equal to this time divided by the nominal rate. However, production records quickly show that this is not the case! This does not take into account all the hazards affecting performance: breakdowns, deviations, micro-stops... and the actual rate which is very often or even always lower than the nominal rate.

Character SESA SYSTEMS maintenance application maintenance TPM method
Character SESA SYSTEMS tool application tool TPM method

The gross operating time cut of the lost time gives the actual operating time, or net operating time. Unfortunately the losses do not stop there. It is obvious that only good parts can be sold to customers. This is the useful operating time.
This diagram below, highlights the proportion of the really useful time compared to the total opening time according to the losses.
Your company's profit is not assured with such a waste! It is important to notice that each "loss" finds its cause in an area that will interest maintenance.
To increase productivity, we must therefore reduce all these losses. It is possible to know with precision the actions to carry out thanks to the OEE, Overall Equipment Effectiveness.

Potential opening time

Real opening time

Plant capacity not used

Gross operating time

Planned stops

Net operating time

Breakdowns, performance losses

Useful operating time

No quality


The ideal would then be:

Zero failure / stop

Zero fault

Zero accidents

In practice this amounts to:

Maintain the equipment in good condition, repair, clean and lubricate it

Penalize production as little as possible

Consider all aspects of maintenance

The 8 Pillars of TPM method with the 5S


In 1989, the JIPM defined 8 pillars on which a TPM approach is based to achieve a high level of industrial performance.
They can be divided into two families of 4:

The first family aims to improve the efficiency of the production system

Autonomous management and maintenance of equipment, elimination of waste / improvements on a case by case basis, planned maintenance and improvement of knowledge and know-how.

The second goes beyond the strict framework of production towards services and related functions

Safety, working conditions and environment, quality control (maintenance), control of product and associated equipment design, efficiency of related services or "TPM in offices".

According to the sources and authors, the number and denomination of the pillars vary. The TPM can be considered as a building with the 5S as foundation and the 8 pillars

The solidity of the whole is linked to the quality of the foundations (5S). If a minimum number of pillars is installed, the building holds. Unlike, if a few pillars fail, the building can still survive. It is therefore not necessary to have all the pillars, nor that they are of identical size/strength to obtain results thanks to the TPM.

Les 8 piliers de la méthode TPM socle méthode 5S

PILLAR 1  

PILLAR 2  

PILLAR 3  

PILLAR 4  

PILLAR 5  

PILLAR 6  

PILLAR 7  

PILLAR 8  

To go further


The TPM-PDCA-SUGGESTION Starter Kit:Simple development of a PDCA board, improvement proposals (suggestion) and TPM(Total Productive Maintenance) as part of a pilot project following the game.

Results: collective and effective success.

TPM-PDCA-SUGGESTION Sesa Systems APPROACH Game Training Box

THE ESSENTIAL TOOLS TO ENSURE THE SUSTAINABILITY OF THE TPM ACTION

SESA SYSTEMS creations for the TPM method