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Total Productive Maintenance (TPM/TPR) Tips


Tip #36  Be sure and conduct a safety walk through before the start of any Basic Equipment Care (BEC) workshop.  Also conduct a safety and lock out review before hitting the floor each day. - (Greg Folts, Marshall Institute Inc.)
Tip #35  Cleaning is inspection! With over 17 years of TPM/TPR implementation experience, it still amazes me how effective cleaning is at exposing defects. I have learned that if I see dirt, I will find defects when we clean.- Greg Folts, President, Marshall Institute - (Greg Folts, Marshall Institute Inc.)
Tip #34  5S is a great preparation activity for Total Productive Maintenance (TPM/TPR). It is fairly easy to implement and generally does not require a lot of maintenance resources. It can help show visible results and demonstrate that change is possible within the current environment. - (Greg Folts, Marshall Institute Inc.)
Tip #33  Brainstorming minor stoppages (less than 10 minutes in duration) with the various operators helps to identify those that need to be tracked and also helps to win the operators' commitment to tracking them in order to remove the recurring nuisances. A checklist on a clipboard with a pencil next to the machine can aid the operator in tracking by marking tick marks for each occurrence. Then, calculating the Mean Time Between Failure (MTBF) can help identify the real culprits and monitor the effectiveness of any solutions.
Tip #32  When calculating a business case, consider the cost of deferring production to a later date. Wages, energy consumption, equipment wear, and overhead are all increased when the product is not produced at the scheduled time.
Tip #31  Quantify the improvements in your Total Productive Maintenance (TPM/TPR) process by documenting improvements in parts cost, equipment efficiency, quality, and reduced oil consumption. Partner with safety and environmental programs by demonstrating the impact of Total Productive Maintenance (TPM/TPR) on safety and the environment - (Greg Folts, Marshall Institute Inc.)
Tip #30  When you provide training to the general workforce, especially the introductory stuff, take it to them on their own turf. Go to them on their shift and make it as convenient for them as possible. When we always bring them in on off time or have them stay over after working all night it works against our best efforts of building that seamless team required for true lasting Total Productive Maintenance (TPM/TPR) success.
Tip #29  Communication is said to be the glue that binds an organization together and it follows that it is an essential part of getting total Total Productive Maintenance (TPM/TPR) buy in from the general workforce. Do not assume that several announcements and a note on the notice board is sufficient to get the story out. At Marshall Institute we say to communicate seven times and seven ways but that does not mean seven months apart. Develop and implement a robust communication plan and check to see if the total target audience has received the unfiltered message. If you want to know if your message is getting out clearly why not ask the most obscure person on the night shift is he or she has the message? The day shift is easy but how about the rest of the folks?
Tip #28  For some maintenance tactics (e.g. Total Productive Maintenance (TPM/TPR) observations, PdM vibration monitoring), direct access to moving equipment is required. This may require changes to equipment guarding. It may be possible to use expanded metal to allow observation of the equipment, while still guarding the equipment. Similarly access for vibration monitoring sensors might be achieved through the use of a suitably sized tube. To simplify removing guards to allow access when the equipment is shutdown and locked out, a standard sized fastener could be held captive to the guard and used to hold the guards in place. To minimize the number of fasteners used to allow quick removal and re-installation, locating pins or hinges (especially those that split into two) can be used with the fasteners.
Tip #27  Create an audit system to ensure your Total Productive Maintenance (TPM/TPR) program is effective. - (James Freds, Advanced Filtration Systems Inc.)
Tip #26  When programs do not align with organization’s goals, they may receive support in the beginning, but if they don’t provide direct value to helping the company meet Total Productive Maintenance (TPM/TPR) goals and objectives, it will only be a matter of time before support and resources dry up.
Tip #25  The most effective TPM implementations are those that integrate well into the organization. The problem is that many programs never quite become part of the organization.
Tip #24  Breakdowns not only prevent you from delivering goods on time, but they add expense to your operational costs. You can keep costs down by being proactive instead of waiting for a failure.
Tip #23  By distributing the tasks and responsibilities around, you not only become more flexible and able to respond to changes more quickly, but you involve more people in the improvement process. Productivity comes from working smarter, not harder. That is the difference between effectiveness and efficiency. You can be effective without being efficient, but, the key to productivity is to do both.
Tip #22  Total Productive Maintenance (TPM/TPR) gives you a system to become more proactive. It encourages planning ahead instead of waiting for failure to arrive. Planned maintenance not only prevents expensive failures, but is far more economical.
Tip #21  Maintenance Prevention doesn't mean eliminating maintenance, it means eliminating costly maintenance by involving operators, maintenance craftsmen and others in activities that prevent equipment from breaking down. This means detecting problems while they are small and manageable.
Tip #20  Develop internal champions for the change process. These “change agents” will make the difference in your implementation, by owning the change. Training, development, and coaching will take these employees to new personal levels and take your Total Productive Maintenance (TPM/TPR) process to the new heights.
Tip #19  The equipment operator can be a valuable resource. They are at the machine far more than maintenance personnel, therefore they are an important resource to detect changes in conditions and perform some of the simpler maintenance tasks such as lubricating, tightening of fasteners, and inspecting for a failure.
Tip #18  Develop a structured root cause analysis approach. Improvement Teams need the structure and process to be effective. We use the Define, Measure, Analyze, Improve, and Control method from Six Sigma in our root cause process.
Tip #17  Early Equipment Management (EEM) is a technique for stopping maintenance related issues at the source. One of the most significant impacts we can have on spare parts, maintenance cost, and operations cost starts at the equipment design and purchase.
Tip #16  Skill transfer is a critical step in the development of operator based inspection. Before transferring a task from maintenance to operations, we must first transfer the skills!!!
Tip #15  5 S is a great preparation activity for Total Productive Maintenance (TPM/TPR). It is fairly easy to implement and generally does not require a lot of maintenance resources. It can help show visible results and demonstrate that change is possible with in the current environment.
Tip #14  Use a root cause analysis process to ensure your Equipment Improvement Teams success. Teams often struggle to solve problems, without the use of a structured problem solving approach. Marshall Institute utilizes the DMAIC (Define, Measure, Analyze, Improve, Control) process to bring structure to the process. This process comes from Six Sigma and is a proven problem solving model.
Tip #13  Partner with other local businesses that are implementing Total Productive Maintenance (TPM/TPR). By networking, your organization can share best practices, share training costs, benchmark with other companies, and reward participation in the Total Productive Maintenance (TPM/TPR) process. This low cost resource can provide great returns!!!
Tip #12  Conduct a team report out at the end of your Autonomous Care events. The team gets a chance to discuss the improvements implemented, as well as discuss support needed to continue improving. Do not let the report outs take longer than 1 hour, and include a visit to the equipment.
Tip #11  Network with other Total Productive Maintenance (TPM/TPR) professionals. Conferences, seminars, and user forums are all good methods of keeping in touch. Conduct a team report out at the end of your Autonomous Care events. The team gets a chance to discuss the improvements implemented, as well as discuss support needed to continue improving. Do not let the report outs take longer than 1 hour, and include a visit to the equipment.
Tip #10  When beginning a Total Productive Maintenance (TPM/TPR) implementation, calculate a business case for the initiative. Develop a picture of cost savings, production improvements, and intangible benefits. Understanding these benefits helps with sustaining and justifying the efforts.
Tip #9  When implementing Total Productive Maintenance (TPM/TPR) find small ways to demonstrate that change is possible. Equipment improvement teams, autonomous care workshops, root cause analysis, and breakthrough teams can all be used to demonstrate "quick wins".
Tip #8  When applying visual controls: Clear packaging tape placed over equipment labels helps with adhesion and protection in harsh industrial environments.
Tip #7  Create a vision for the change desired with the Total Productive Maintenance (TPM/TPR)process. Once your key leaders agree on the vision, you can start to communicate the vision to the employees. Tie all Total Productive Maintenance (TPM/TPR) activities with the vision. Ask: How does this action support the vision?
Tip #6  Visual Controls are used to reinforce standards and to help the operator tell "normal from abnormal".
Tip #5  Standards are the key to accountability and the elimination of variation. The standard defines the expectation so the quality of the task can be audited and encouraged.
Tip #4  Always begin your Total Productive Maintenance (TPM/TPR) implementation with an assessment of your current status. The assessment will establish a baseline, understanding of the current environment, and a basis for future audits.
Tip #3  Always build a strong support system for your Total Productive Maintenance (TPM/TPR) process. Long term success and sustainability requires a broad support structure. Ensure that if one key supporter for the process leaves, your process will not fail.
Tip #2  Brainstorming minor stoppages (less than 10 minutes in duration) with the various operators helps to identify those that need to be tracked but also helps to win their commitment to tracking them in order to remove the recurring nuisances. A checklist on a clipboard with a pencil next to the machine can aid the operator in tracking by marking tick marks for each occurrence. Then calculating the Mean Time Between Failure (MTBF) can help identify the real culprits and monitor the effectiveness of any solutions.
Tip #1  Keep in contact with the Total Productive Maintenance (TPM/TPR) professionals at Marshall Institute. We are in facilities from Atlanta to Russia assisting with implementation efforts. Call us with your questions, comments, or to share your latest success with Total Productive Maintenance (TPM/TPR). We love to hear from the field!!!

Updated November 1, 2010


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