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Traffic Maintenance – TPM
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TPM
Total Productivity Maintenance (TPM) is one of the most important tools for effective management of manufacturing companies. Defined in Japan in the 70s, it has proven effective in factories worldwide, increasing efficiency, improving quality, reducing costs, and ultimately increasing profits. TPM is based on the premise that engaging all employees in building an effective prevention system, systematically reducing losses through problem solving, and standardization are key to achieving the triple zero goal: zero breakdowns, zero defects, and zero accidents. TPM is a tool used in companies such as Volvo, FIAT, Iveco, Mirelli, Unilever, PepsiCo, Wrigley, and Heineken.
Benefits for TPM training participants:
- learning the principles that should be followed in maintenance structures
- preparation of operating instructions for maintenance levels TPM1 and TPM2
- developing a method for collecting data to record procedures and activities related to maintenance according to the TPM strategy
- creating a schedule for the inspection of machines and devices in the maintenance department
Why is it worth working with us:
- we operate innovatively, effectively, flexibly and quickly,
- we focus on quality and practical results, as evidenced by the positive opinions of training participants and their repeated choice of our company,
- we value a very good atmosphere of cooperation and mutual trust,
- we focus on a professional and competent approach to the client,
- we use systematic and advanced monitoring of our services,
- we are open to all suggestions, comments and proposals from our clients,
- we have proven, experienced staff who are constantly improving their qualifications,
- We place great emphasis on precisely adapting training forms, processing methods and programs to the client's needs,
- we build long-term relationships with our clients based on mutual satisfaction.
Knowledge in a nutshell
Maintenance of machinery and equipment
Various strategies have been developed for maintaining operations and equipment. These include both simple and complex strategies. Each has its advantages and disadvantages. It's worth considering their characteristics, as this allows you to decide which strategy to implement. Some involve high costs that significantly outweigh the losses. What is maintenance, what strategies are available, and which one is best? The most important information is provided below.
What is maintenance and what does it involve?
Maintenance is a crucial area of operation for every manufacturing company. Its efficiency, and ultimately, profitability, depends on maintenance. Historically, maintenance was associated solely with services responsible for repairing breakdowns and faults in machines and entire production lines. As long as the entire machinery was operational, maintenance intervention was unnecessary. Today, this area has been defined somewhat differently, and maintenance is considered from two perspectives. On the one hand, these are activities aimed at preventing breakdowns. On the other hand, these are all activities that previously served to repair them. It's difficult to expect machines to function flawlessly throughout their lifespan. Periodic breakdowns are a natural part of their operation. However, it's important to prevent them whenever possible, and when unavoidable, respond as quickly as possible to minimize the extent of damage and thus reduce the cost of repairing or replacing a damaged part.
What are the maintenance strategies?
There are many different options available today when it comes to maintenance strategies. These include corrective, preventive, and complex techniques. Complex techniques utilize the foundations and assumptions of simple techniques.
Within the group of corrective techniques, reactive and predictive strategies are available. Preventive techniques are diverse.
To fully understand the essence of this issue, individual strategies and techniques are described below.
Reactive maintenance
Reactive maintenance was previously the most commonly used strategy, but due to its high costs, it has been largely phased out. Reactive maintenance is based on the assumption that no action is taken as long as nothing is happening and machines are operating properly. As a result, reactive maintenance activities were implemented only after a breakdown or malfunction. Some reasons for downtime are not serious. A device simply needs to be cleaned or slightly modified to function properly again. Sometimes, however, the cause of the downtime is more serious. In such cases, it is necessary to repair the damaged part, replace it, or repair/replace the entire assembly. This approach results in very high repair costs, which in turn increases production costs.
Predictive maintenance
A slightly different strategy from the corrective group is predictive maintenance. It is based on the assumption that as long as all machines are operating efficiently, the maintenance department will not take action. However, when the first indications of an impending failure (machine malfunction) appear, action is taken immediately. This strategy involves not waiting for a failure but rather attempts to prevent it. However, it is a corrective strategy because it anticipates the first signs of machine malfunction and takes corrective action.
Corrective methods can be divided into immediate and deferred. Immediate methods require immediate action (e.g., a reactive strategy), while deferred methods allow for action to be postponed (e.g., a predictive strategy allows a machine with signs of failure to continue operating for a while).
Preventive maintenance techniques
Preventive maintenance techniques primarily serve to prevent equipment failures and damage. Systematic work is undertaken, such as inspections and maintenance, which involve monitoring the equipment and its technical condition. If a part shows signs of excessive wear, it is immediately replaced, before symptoms of impending failure or actual damage occurs. Inspections are conducted regularly, with the intervals between them depending on the type of equipment and its failure rate. Such inspections can therefore occur every few weeks, every few months, or even every few years. The number of machine hours used or products produced can also be a metric for conducting inspections.
It's also important to consider whether a given machine operates with a consistent load throughout the season. It may be that it operates significantly more heavily or more intensively during certain seasons. During such periods, inspections should be intensified and their frequency increased. If the equipment's use increases, then, naturally, its failure rate also increases, hence the need for more frequent inspections.
The inspection doesn't just include a technical inspection of the device. Maintenance is also performed. The device is cleaned, lubricated, and, if necessary, serviced. If any part is excessively worn, it is replaced immediately, without waiting for further wear, which could lead to damage.
Complex techniques
Complex techniques involve combining simple techniques and designing maintenance crews' work to simultaneously address both preventive and corrective actions. This protects machines from damage when it is unavoidable, and action is taken immediately upon the first signs of irregularities or immediately after a machine failure. Implementing complex techniques requires appropriate training for maintenance crews. It is important to precisely characterize the individual basic techniques that comprise a complex technique.
