TOTAL
PRODUCTIVE MAINTENANCE
SSA
specializes in developing and
delivering a customized plan
for implementing TPM or Total
Productive Maintenance for the
Corporate. Based on the requirement
of the Clients, SSA roadmap
comprises of knowledge transfer
through trainings, and specific
handholding to achieve the highest
overall effectiveness of equipment
for the Clients.
Total Productive Maintenance
(TPM) is a maintenance programme
for maintaining plants and equipment.
In the Manufacturing industry,
'Machines' are considered as
the most important resource
after 'Man' or Human resource.
It is of utmost importance to
have full machine utilization,
failing which the Organization
manufacturing cost rises up.
The TPM Program aims at increasing
production, while simultaneously
increasing employee morale and
job satisfaction. The TPM program
is similar to the popular Total
Quality Management (TQM) program.
Many of the same tools such
as employee empowerment, benchmarking,
documentation, etc. are used
to implement and optimize TPM.
Maintenance of Machines in industries
traditionally started with 'Breakdown
Maintenance', ie, making amends
after the damage has happened.
The next level of improvement
was into 'Preventive Maintenance'.
This aimed at prolonging the
life cycle of machines &
equipments through preventive
care. The next generation maintenance
was 'Predictive Maintenance'.
This was one step ahead of the
earlier programs. Instead of
covering all parts under a prevention
of breakdown plan, only a few
critical parts were identified,
monitored for performance and
pattern of breakdown. Thus,
instead of applying prevention
to every part, only select part
performance was predicted and
suitable actions taken to mitigate
damage.
Total Productive
Maintenance (TPM) came in as
the latest and 4th Generation
theory. This looks at Machine
utilization, owing to breakdown,
as not the only factor for inefficiency.
As per the TPM philosophy, there
are 3 aspects that affect the
Overall Equipment Effectiveness
(OEE):
Thus, as per the above, the overall
equipment effectiveness or OEE
is a function of the following:
Machine Utilization
X Machine Performance X Quality
If the Machine Utilization
is 90 %, Machine Performance
is 90 % and Quality is 90 %;
the overall equipment effectiveness
comes to 0.9 x 0.9x 0.9 = 0.729
or 72.9 % only !
By addressing the effectiveness
for all 3 parameters together
TPM helps to raise the overall
effectiveness of the equipment.
Thus, TPM impacts the effectiveness
of the most precious equipment-
Capital Investment. Simultaneously,
it indirectly addresses other
System related issues within
the organization. It contributes
to raising the profitability
of the organization, while reducing
the cost substantially. In other
words, it contributes to the
bottom line of the organization
by stopping resource leakage
within the Company.
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