Total productive maintenance (TPM) is a concept that has a huge impact on most of the Key Performance Indicators (KPIs) of a production. These KPIs include:
– Productivity (value added per employee, working productivity)
– Quality (number of bad parts or number of customer claims)
– Costs (maintenance costs, energy costs)
– Storage (warehouse frequency, value of the storage)
– Work safety (number of accidents, number of missed working days due to accidents)
– Employee involvement (number of improvement proposals by employees, improvement workshops)
TPM influenced all of these KPIs. The best KPI for checking the efficiency of TPM implementation is the “overall equipment efficiency” (OEE).
The three main categories of equipment-related losses—downtime, speed loss, and defect or quality loss—are also the main ingredients for determining the OEE. Overall equipment effectiveness is calculated by combining three factors that reflect these losses: the availability rate, the performance rate, and the quality rate.
To calculate OEE, we multiply the three factors together:
OEE = Availability Rate x Performance Rate x Quality Rate
Every responsible person should read about the philosophy of TPM in order to be capable of implementing it. As with most of these kinds of systems, you will be successful with the implementation only if the management understands the concept exactly. The TPM philosophy is based on eight pillars:
- Continuous improvements: The target is to achieve zero defects in all production processes.
- Autonomous maintenance: Machine workers provide inspections and smaller levels of maintenance by themselves.
- Preventive maintenance: Assurance must be given that the machines are always ready for production.
- Employee training: The target is to improve employees’ usage and maintenance capabilities.
- Equipment monitoring: The startup time for machines will be shortened.
- Quality management: excellent quality due to elimination of all bad parts
- TPM in administrative areas: Waste is eliminated in non-producing departments.
- Work safety and health protection: The target is to have zero accidents in the company.
Founded on these eight pillars, the TPM system is developed.
If a company starts to implement TPM but has no experience with doing so, it should involve an experienced consultant in the beginning. Doing so is very powerful in implementing the TPM philosophy in a company. An old wisdom says: The prophet in his own country is less powerful than fresh blood. However, it is necessary that management together with the consultant pushes the process.
TPM improves much more than simply the equipment availability: If the implementation process is well set up, it will ultimately change company culture.