Progim Lean Transformation & Software

(TPM) - Total Productive Maintenance

TPM-Total Productive Maintenance: Zero Failure, Zero work accident, Zero defect…

What Is Total Productive Maintenance (TPM)?

Total Productive Maintenance (TPM) is a “Company Strategy” aiming at zero downtime in production processes, zero quality defects and zero work accidents, bringing autonomous maintenance responsibility to the operator with the participation of all employees, maximizing efficiency of the production system and equipments.

With the realization of TPM, significant financial gains are obtained as follows:

  • Productivity increase
  • Decreased failures
  • Decrease in product defects
  • Decrease in work accidents
  • Decreased customer complaints
  • Decrease in semi-finished good stocks
  • Decrease in maintenance costs
  • Increase in employee suggestions

The following gains of total productive maintenance (TPM), which cannot be measured, also contribute to the development of the company:

Which cannot be measured:

  • As a result of autonomous maintenance activities, operators start to adopt their machines.
  • The belief of “Zero Failure”, “Zero Work Accident”, “Zero Defect” becomes widespread.
  • Cooperation between departments increases
  • Information sharing becomes widespread
  • The working environment becomes cleaner and tidy

As the total productive maintenance works begin to settle in the factory, machine operators become maintenance operators, and maintenance personnel become improver maintainers.

In other words, downtime is so reduced over time that maintenance workers now turn to jobs such as early equipment management and construction of new machinery / equipment instead of repairs.

Total Productive Maintenance
(TPM) - Total Productive Maintenance
(TPM) - Total Productive Maintenance

Things to be done for the realization of TPM are defined as 8 columns of TPM in 8 separate topic headings as shown in the picture.

Progim enables you to realize 8 columns of TPM in your company in order to achieve all the above targets.

  1. Kobetsu Kaizen: Kobetsu Kaizen means focused improvements. It includes "Problem Solving Systematics" performed in 10 steps. A large number of Kobetsu kaizen team studies are carried out to ensure that the OEE (Overall Equipment Effectiveness) value, which is the most important key performance indicator of TPM, is getting better. “16 Major Losses”, which reduces the efficiency of the factory, are minimized with these efforts.
  1. Autonomous Maintenance: In autonomous maintenance, operators perform maintenance activities on the machines they are responsible for. operators adopt their machines.In this way, both the downtimes are reduced and the operators become more aware of the arrival of the fault before the fault occurs.
  2. Planned Maintenance: The maintenance department carries out preventive maintenance (Periodic-Predictive maintenance-revision), corrective maintenance and maintenance prevention activities within the scope of planned maintenance.
  3. Quality Maintenance: It includes the activities carried out to minimize internal and external quality losses. It aims to find out solutions by determining the problems that may occur in the product beforehand.
  4. Training: The basic training policy of the factory is drawn up, internal and external trainings help improve the skills of all employees and contribute to TPM practices.
  5. Office TPM: It aims to ensure the flow by eliminating waste in indirect processes. Autonomous maintenance is carried out in the offices and improvements are provided in the process with kobetsu kaizens.
  6. Safety and Environment: It is for reaching “zero work accident” which is one of the most important targets of TPM. It also aims to prevent environmental damage with factory waste.
  7. Early Equipment / Product Management: It aims to realize the maintenance-free machine concept. For this, past experiences (good-bad) are gathered in a common data base for use in new purchases. The same concept is used in developing new products.