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Continuous Improvement of Quality
Published in K. S. Krishnamoorthi, V. Ram Krishnamoorthi, Arunkumar Pennathur, A First Course in Quality Engineering, 2018
K. S. Krishnamoorthi, V. Ram Krishnamoorthi, Arunkumar Pennathur
Preventive maintenance mainly involves oiling and greasing of seals and bearings at the optimally scheduled intervals, and keeping the machinery clean. When the machines and their surroundings are kept clean, any leaks, which, if left unobserved and unattended might lead to major damage to equipment, will be visible as soon as they occur and can be repaired. The TPM approach recommends autonomous maintenance in the sense that the production workers who are in charge of operating the machinery take responsibility for the regular oiling, greasing and cleaning of production machinery without the assistance of the maintenance crew. Thus, a few minutes spent by workers in a day go a long way in preventing machine breakdowns, and spare the maintenance crew valuable time which they can use in other more productive functions in the upkeep of machinery for improving their reliability and longevity.
Visual Maintenance and Total Productive Maintenance Boards
Published in Chris A. Ortiz, Murry R. Park, Visual Controls, 2018
With a TPM program in place, they can respond better with preventive maintenance steps to reduce equipment breakdowns. As breakdowns do occur, they are better prepared with readily available tools and the knowhow to respond. Posting machine information allows them to see a potential problem before it occurs and provides an opportunity for operators to assist in seeing unfavorable trends before a bad part is made. Posted information shows what Level-1 PM work has been performed. Technicians are being cross-trained and are recording the status of each piece of equipment and collecting quantifiable breakdown data. Management has backed off a bit to give them some breathing room. They have a workable plan. In essence, their entire team has been completely refocused to concentrate on its original purpose.
Lean Preparation
Published in Gisi Philip, Sustaining a Culture of Process Control and Continuous Improvement, 2018
Unpredictable equipment availability forces many operations to increase inventories to buffer against unexpected downtime or to invest in additional equipment to compensate for the shortfalls of existing equipment. A key to improving equipment reliability is total productive maintenance (TPM). TPM is a production discipline intended to optimize equipment and machine performance throughout their expected life span using known maintenance techniques and total workforce engagement. If executed properly, TPM could increase operational efficiency with minimal investment in maintenance. A good TPM program leverages lessons learned, best practice and standard work procedures to improve maintenance efficiency and effectiveness.
Kaizen practices and performance improvement in Zambian manufacturing companies
Published in Cogent Engineering, 2023
Chanda Sichinsambwe, Peter Lubosi Simasiku, Shem Sikombe, Harris Nyimbili
TPM stands for “Total Productive Maintenance” and establishes a close relationship between Maintenance and Production, suggesting that good maintenance and upkeep will lead to high productivity. The main objective of TPM is to maximize overall equipment efficiency by eliminating or reducing losses. The purpose of productive maintenance is to improve plant and equipment efficiency to achieve optimal life cycle costs for production equipment. Therefore, the benefits of TPM include productivity and OEE (Overall Equipment Effectiveness). TPM requires motivation and inspiration from the workforce to be successful and effective (Nakajima, 1988). TPM generally reduces six losses—equipment failure, downtime, setup time, work defects, low productivity, and slow speed (Macaulay, 1988).
Manufacturing productivity analysis by applying overall equipment effectiveness metric in a pharmaceutical industry
Published in Cogent Engineering, 2021
Muhammad Zubair, Shahid Maqsood, Tufail Habib, Qazi Muhammad Usman Jan, Uroosa Nadir, Muhammad Waseem, Qazi Muhammad Yaseen
OEE measures the total equipment performance which is the degree to which the equipment is doing, what it is supposed to do (Williamson, 2006). OEE is an important tool which identifies areas that may have bottleneck in the production line (Omega & Andika, 2017), covering three major aspects such as the availability, performance, and quality rate of the output of equipment. OEE is considered as one of the important content for total productive maintenance (TPM) and lean manufacturing philosophy (Lin et al., 2017). Additionally, it is an important metric for measuring the success of manufacturing improvement approach known as Total Productive Maintenance (TPM) (Nakaiima, 1988). TPM is an innovative Japanese concept that is mostly followed for optimizing equipment effectiveness, breakdowns elimination and promoting autonomous maintenance in day to day activities involving total workforce (Mahajan et al., 2018). It usually seeks to maximize the effectiveness of the equipment during its entire life. TPM consists of three words (Fam et al., 2018); Total: means involving the entire workforce from top to bottom in equipment maintenance. Productive: means to ensure that the operation is efficient maintenance problems/costs. Maintenance: ensuring that the equipment is in good condition.
Improvement of productivity by implementing occupational ergonomics
Published in Journal of Industrial and Production Engineering, 2022
TPM acts as a significant aspect to enhance productivity and overall equipment efficiency. TPM is illustrated by Seiichi Nakajima in the seventies of the twentieth century [2]. It is a maintenance program that defines the approach for sustaining plants and machinery. The objective of this program is to increase production, employee morale, and job satisfaction [17]. It aims at the improvement of an enterprise through radical reforms in equipment and personnel [18]. It states that TPM involves eight pillars, resulting in increased labor productivity through self-controlled maintenance, reduced maintenance costs, and production stoppages and downtimes. Eight pillars with 5S can achieve the goal of TPM followed, as shown in Figure 2 [19]. The summary of the eight pillars is given in Table 1 [19,20]. 1.Autonomous maintenance (Jishu Hozen)Focused Maintenance (Kobetsu Kaizen)Planned MaintenanceQuality MaintenanceEducation and TrainingSafety Health and EnvironmentOffice TPMDevelopment Management