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TPM maintenance workstation

Achieve a zero failure objective with TPM (Total Productive Maintenance)

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

TPM, or Total Productive Maintenance, is a method which improves the productivity of your equipment by reducing downtime and breakdowns while optimizing productivity, quality and other performance indicators. TPM is one of the steps of Lean Manufacturing.

What is TPM?

TPM is a practice aimed at building a corporate culture that improves the efficiency of the production system. It allows the gradual transition from a curative maintenance system to preventive maintenance (or even predictive maintenance in some cases).

This is the result of a managerial focus on :

  • Establishing a Continuous Improvement Policy
  • Involving all staff by empowering them
  • Improving performance QUALITY / COSTS / DEADLINES
  • Improving equipment (productivity, efficiencies, etc.).
  • TOTAL

    Considering all aspects of maintenance and hold everyone accountable to ensure all standards are met.

  • PRODUCTIVE

    Ensuring maintenance by limiting production penalties as much as possible.

  • MAINTENANCE

    Spending necessary time on maintenance: repair, clean and grease machinery.

History of TPM

TPM was developed in Japan and succeeded the American Preventive Maintenance (PM)  just after the Second World War. TPM was introduced in the factories of the Nippondenso group before being formalized by the JIPM, Japan Institute of Plant Management, who hold the registered trademark of TPM. In 1989, the JIPM defined 8 pillars on which a TPM approach is based to achieve a high level of industrial performance. What has changed in relation to PM is the participatory approach, the active participation of operators who know their machine(s) and therefore contribute effectively to its maintenance.

TPM GOALS

Purpose of the TPM approach

The TPM approach focuses on the machine and is increasingly becoming the first step in launching performance improvement initiatives.

To adapt the TPM approach, companies must eliminate unexpected and chance occurences in their production activities. 

To efficiently utilize TPM, a site needs a reliable and available production tool.

SESA SYSTEMS Mascot Maintenance
SESA SYSTEMS Mascot TPM tools

TPM makes it easy to visualize in graphical form (Pareto, curves, etc.) the main indicators and factors that influence results. These graphs provide reports, based on TPM criteria, that deliver personalized analysis and projections for  specific durations or resources.

The purpose of the data analysis is to determine the main causes of underperformance and to specifically highlight actions that generate gains, specifically of TRS (Synthetic Rate of Return).

TPM systems have three major objectives:

Minimize financial and production losses due to the underuse of equipment.

Conserve equipment with maintenance monitoring carried out in real time.

Improve organization and act on factors that allow you to obtain the best returns.

Advantages with TPM

Workforce Benefits

  • Communicate and involve everyone
  • Reconsider your habits
  • Maintaining
  • Making sustainable the results achieved and progressing continuously
  • Respecting commitments and collective rules
  • Example of a TPM workstation
    Example of a TPM workstation

    TPM Maintenance Station

    The maintenance station is associated with each machine or manufacturing cell requiring immediate availability of tools for:

    • Meeting preventive maintenance requirements
    • Reducing of space requirements
    • Optimizing work space and ensuring it is clean, tidy and rational for production efforts
  • Exemple Poste de propreté de maintenance TPM
    Exemple Poste de propreté de maintenance TPM

    TPM cleaning station

    TPM cleaning stations offer a complete office, warehouse and service solution:

    • Increases in organization and quality of work
    • Encourages productivity and efficiency
    • Reduces accidents and technical breakdowns or malfunctions
  • TPM Bulletin board
    TPM Bulletin board

    TPM Visual Communication Support

    The communication panel's management of anomalies is utilized in large industrial groups, allowing operators to:

    • Express yourself in real time and without constraint
    • Implement changes quickly, efficiently, and economically
    • Encourage better overall performance

    SUCCEED IN ITS TPM METHOD

    The TPM (Total Productive Maintenance) approach improves the production capacity of technical resources by building a system that avoids losses and waste such as "zero accidents, zero faults and zero breakdowns". This technique is based on fieldwork (Gemba) and concret (Genbutsu) throughout the life cycle of the production system.

    The TPM requires the participation of all divisions, not only those related to production but also the conception of production, development, marketing and administrative services, at all hierarchical levels, from managers to operators.

    It enables companies to reach "zero losses" by engaging in small group improvement initiatives. Everyone is encouraged to find an advantage in the TPM approach - and is not always the financial aspect even if it is highlighted. Taking the time to uncover the diverse advantages of TPM can uncover deeper issues, allowing workers to remove the proverbial "thorn" in their side.

    This thorn can be the routine that one perceives, the attitude of the hierarchy, the feeling of not being heard, the difficulties that one encounters to carry out work in normal conditions (difficulties due to the material, the raw materials, the organisation, ergonomy issues, etc.). This thorn can also be the need to feel useful and solve problems on ones own.

    TPM method training game

    PLAY-BASED TRAINING FOR THE TPM METHOD

    A fun e-learning game for professionals

    Average duration: 2h30

    This play based training method relies on the concept of travelling in a car and is presented in a form of the "Game of Goose," sown with hazards, one tries to eliminate sources of dysfunction in production (both external and internal).

    Don't wait any longer to train your colleagues.

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

    Results: collective and effective success.