TPM - Total Productive Maintenance

What is TPM?

TPM is a holistic concept and approach to increase overall equipment efficiency and develop the company’s productive processes. TPM puts the focus on both production and equipment as well as People. Everyone in the company is committed to eliminating all types of losses. Be it in machines, equipment or processes in to optimize OEE – “Overall Equipment Effectiveness” providing control that in turn creates safety, utility and value.

Benefits

Reduction of maintenance costs
Successfully implemented TPM projects can significantly reduce maintenance costs. More regularly simple preventive maintenance, such as lubrication, replacement of wearing parts and inspections of certain machine parameters, reduce the likelihood of major and more expensive repairs and production losses.
Improved equipment efficiency
Errors, speed losses and quality errors in production are costly. These can in many cases be reduced or completely avoided. The introduction of TPM reduces downtime costs and increases production capacity.
Improved teamwork and employee engagement
Introducing TPM measures will build an extended understanding of the responsibilities between different departments in your organization. This gives your production staff a better understanding of the work of the maintenance team and vice versa. It enables all participants to work with solutions, improvements and optimizations across departments.

TPM - Fabrik

Common Issues

TPM stands and falls with planning and documentation. If TPM isn’t planned properly and/or is inconsistently documented, many of the TPM related activities will be in vain. Maintenance activities may be performed twice since the team may not know which activities have already been performed or incorrectly executed tasks can cause even greater damage.

TPM Challenges for your business

TPM is a well-known subject to many in the industry. We are all aware of the challenges that the implementation imposes on both the production and the maintenance department. For the production staff to execute maintenance tasks raises questions of structure, organization and guidance.

TPM requires a clear definition of tasks, responsibilities and the scope of documentation. This is particularly important in order to ensure compliance with certain standards such as IATF 16949 and ISO 9001. This means that you must have documentation and evidence at your disposal, at the latest before an audit. But significantly better is to always be in control, because TPM is supposed to increase the availability of your machines and not just satisfy auditors.

This means that you must be in control of the following parts:

  • Instructions
  • Work permits and risk analyses
  • Scheduled and recurring tasks
  • Follow-up of carried out and delayed actions
  • Documentation of implementation with name and time
  • Possibility of analysis of data and information

This can of course be handled in Excel or on paper. The more effective option is to map this in your maintenance systems so that the necessary structure is provided for the long term. This way, everything is in one place and there is a common thread through all past activities so that everyone can work on continuous improvement.

TPM-Activities in MaintMaster

 

MaintMaster is the maintenance software that also handles TPM activities in the production.

MaintMaster covers everything related to maintenance, so why not also TPM activities? Nothing comes more natural. MaintMaster covers all the above mentioned with ease and by far better than pen, paper or spreadsheets do.

Instructions
Guidelines and instructions that you set and use over and over again
Work orders
Create TPM activities as a custom category in MaintMaster
Recurring tasks
Set up recurring activities so they’ll never be forgotten
Follow-up on tasks
Automatically show status of tasks
Documentation
Document with name and time: Users and timestamps on digital documents simplify reviews and audits
Analysis of data and information
Turn and flip information, automatically view statistics, and export to Excel as needed

There is more you can do of course: Setting up and managing planned and actual time spent on TPM tasks. Your TPM activities can be easily mapped in MaintMaster and you have every opportunity for digital evaluation.

TPM-User in MaintMaster

MaintMaster offers a simple solution to create support for TPM, so that entire production staff gets the support and guidance that they need.

TPM Question

 

MaintMaster is billed per user:

Do I need to buy user accounts for the entire production department?

TPM Answer

 

Your production staff has to have the permission to report in MaintMaster but there is a designated permission level for TPM users that is billed in bundles.

Implementation of TPM

Over the years, our team of sales people and project managers has gained valuable experience in the introduction of TPM activities. Contact us to integrate TPM activities into your work processes.

Johan Peterson

johan.peterson@maintmaster.com