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Total Productive Maintenance

 Javier Osuna
Mechanical Engineer


Since the birth of industry to this day, we have implemented maintenance to all types of machinery. However, in many enterprises today, it is not properly developed; thus, the great importance of Total Productive Maintenance (TPM).


TPM was born in the United States in the 50's, resulting from preventive maintenance that was performed on equipment as planned actions pertaining to partial revision, lubrication and spare part replacements, all on a specific schedule or before their failure, among others.

It is based on a methodology of improvement, which ensures the availability and reliability of equipment and system operations, by applying the following concepts: Prevention, No defects, No accidents, and, most importantly, the total engagement of all team members.

The reference to total engagement of team members is due to the fact that maintenance activities on equipment should not only be carried-out by maintenance staff, but also by trained staff, production staff and equipment operators.

The main objective of TPM is to ensure that a piece of equipment or production tool remains in an optimal state for its use, and that it is capable of producing parts with adequate quality standards and within the specified time limit.

TPM focuses its objectives towards improving the efficiency of equipment and operations by reducing failures, inter-departmental nonconformities and change times; and likewise, is related to maintaining order and clean-up activities.

TPM image


THE IMPLEMENTATION OF TPM IN A COMPANY

The steps required to develop a change of attitude are the following:

1. INITIAL CLEANING
In this phase, we seek to clean the dust and dirt from the machine, in order to leave all of its parts perfectly visible.

2. MEASURES TO DISCOVER THE ROOT CAUSES OF DIRT, DUST AND BREAKDOWNS
Once the machine is cleaned, it is essential that it does not get dirty again, and fall into the same state.

3. PREPARATION OF CLEANING AND LUBRICATION PROCEDURES
In this phase, standard procedures are prepared so that cleaning, lubrication and the minor adjustment of parts may be carried-out in a short amount of time.

4. GENERAL INSPECTIONS
Once personnel has taken full responsibility for the cleaning, lubrication and minor adjustments, the production staff is trained to inspect and check the equipment for minor faults and failures in the gestation phase, and, of course, to resolve them.

5. INDEPENDENT INSPECTIONS
In this fifth phase, ranges for independent maintenance or operational maintenance are prepared. Checklists for the machines are prepared by their operators, and put into practice.

6. ORDER AND HARMONY IN THE DISTRIBUTION
It seeks to create procedures and standards for the cleaning, inspection, lubrication and keeping of maintenance records that reflect all maintenance and production activities, tool and spare part management, etc.

7. OPTIMIZATION AND ACTIVITY INDEPENDENCE
Its objective is to develop a culture towards continuous improvement throughout the company. The time between breakdowns is systematically recorded, analyzed, and solutions are proposed. All this is encouraged and led by the production team itself.

Carrying-out a good implementation of TPM achieves a high positive impact on productivity, quality, costs, inventories, staff motivation and safety. Additionally, intangible benefits are obtained, that focus on:
• Improvement of the workplace.
• Clean and orderly work places.
• Knowledge, skill and motivation improvement for all employees.
• An increase in employees´ sense of belonging.
• Change in the organizational culture.
• Improvement in communication and respect between work areas.

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