tpm essay - 1st part

8/11/2019 TPM Essay - 1st Part

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1. TPMTOTAL PRODUCTIVE MAINTENANCE

Total Productive Maintenance - TPM is a management model that aims toincrease the productivity and competitiveness of an industry through improvements in

equipment, that it desire zero fault and zero breakage of machinery and consequently

the zero defects in products and zero loss in the process.

Preventive maintenance emerged in the United States, around the year 1950 and

has been enhanced by the Japanese, being the basis of the TPM. The TPM was initially

developed in the automotive industry and quickly became part of the organizational

culture of companies like Toyota, Nissan and Mazda, and yet its suppliers and affiliates.

The main objectives of TPM are zero defects, zero losses, zero accidents, zero

breakdowns, zero failures, gains in productivity and competitiveness, efficiency gains,

improved quality, no rework or adjustments to work with safety and comfort.

The main features of the TPM are: participation of all departments and

employees, establish goals for the elimination of losses, development the mindset of the

people using the equipment as a learning material, make the TPM one routine work,highlighting the activities (make visible - frame of activities), reduce costs (TPM must

be profitable).

The deployment of TPM the company achieves tangible and intangible benefits.

The tangible benefits are: safety (zero accidents and zero defects), productivity

(productivity gains, reduced breakage), cost, inventory (inventory reduction), quality

(reducing defects). Already intangibles are larger organization and cleanliness of the

work environment, reducing breakage and defects causes the operators improve their

confidence.


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Figura 1: TPM PillarsFonte: https://www.industryforum.co.uk/expertise/manufacturing-operations/tpm/

Below is the definition of each of the 8 columns that make up the TPM.

1.1 Focused Improvement

The Focused Improvement is characterized by eliminating large losses,

increasing the overall effectiveness of equipment. Making great improvements, changes

and methods in order to increase the efficiency of the equipment.

The practice indicates that it is easier and effective do improvement activities in

stages, documenting the visually progress as procedures. The steps are:

Selection of Equipment / Process as Model;

Constitution and Training Working Groups;

Survey of Current Losses;

Definition of Themes and Goals for Improvement;

Development of Improvement Plan;

Mapping of analysis and Countermeasures;

Implementation of Improvement;

Proof of Income;

Providence to Prevent Recurrence;

Dissemination of Improvements Implemented in equipment / processes.


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1.2Autonomous Maintenance

According to Souza (2006), Autonomous Maintenance aims to eliminate large

losses and increase the overall effectiveness of equipment through the activities of small

groups, causing the operator to acquire knowledge and skills related to your equipment.

Such maintenance operators are trained to supervise and act as maintainers of the first

level. The expression "I'll take care of my machine" is the keynote of this maintenance

(Nakajima, 1989).

1.3Planned Maintenance

The planned maintenance program is touted as success in managing processes.

The mechanical interventions on the equipment become, mostly programmed by

optimizing the equipment stop and improving productivity.

According to Souza (2006) concept of the philosophy of Planned Maintenance is

the awareness of losses arising from equipment failures and changes in mentality of the

Divisions of production and maintenance to minimize these flaws and defects with

minimal cost.

1.4Training and Education

According to Souza (2006) the pillar of education and training is responsible for

providing resource to the production departments, maintenance, and management skills

and acquire knowledge about the equipment and mainly about the philosophy of TPM.

Thus, they will believe in the work to be done, which will result in increased

productivity, reduced losses and improved quality. Training is an investment that should

not save, because the return is guaranteed. Activities related to this pillar are: Perform

audits, reduce the doubts regarding TPM, among others.

1.5Early Management

For Souza (2006), the major objective of this pillar is the development of thetechnical specification of machinery and equipment, analyzing requirements and


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specifications adopted by the TPM, mediating the claims of the other pillars of the

program. The pillar acts together with the pillar of Autonomous Maintenance. The fifth

pillar is directly linked to the acquisition of new equipment, modernization of processes

and systems, based on experience and applying such projects, thinking about the

integration between man and machine taking into account environmental conditions and

production.

1.6Quality Maintenance

The pillar aims to act in the elimination of losses related to the quality of

equipment, assisting in troubleshooting, establishing conditions on equipment that does

not produce defects in the final product. According to Souza (2006), the support areas to

ensure Zero equipment breakdown and Zero defects in the product is critical to decision

through data analysis, evaluation of causes, conduct audits, and constant search for

greater reliability in product and process. It is recommended to use the Decision

Diagram.

1.7Office TPM

Also known as "Maintenance of Offices", according to Souza (2006), the pillar

"Office TPM" aims to reduce losses in administrative processes, eliminating rework

non-value added , increasing the financial efficiency and yields of equipment and

machinery, besides seeking the expansion of knowledge needed for inventory

management and logistics, helping to solve problems of flows in the administrative

proceedings.

1.8Safety, Health & Environment

According to Souza (2006), the main objective of the pillar is to implement the

principles of environmental management at the factory, through measures that minimize

environmental impact, ensuring the safety and health of each stakeholder in the process,

also reducing waste and generating increased productivity by reducing accidents.

Among the priorities of the pillar are: fetching zero accidents through reliable

equipment, prevention of human error, and equipment and processes that do not harm

the environment.

tpm essay - 1st part

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