IATF 16949:2016 Clause Total productive maintenance

Please click here for Total productive Maintenance

The standard requires implementation of Total productive maintenance to ensure continuing process capability and to identify key processes and provide appropriate resources for machine/equipment maintenance and develop an effective planned total productive maintenance system. In a manufacturing environment, this requirement applies to the process plant, machinery, and any other equipment upon which process capability depends. The requirement for documented process implies that you will need process for maintaining this equipment and this means that you will need:

  • A list of the equipment upon which process capability depends
  • Defined maintenance requirements specifying maintenance tasks and their frequency
  • A maintenance program that schedules each of the maintenance tasks on a calendar
  • Process defining how specific maintenance tasks are to be conducted
  • Process governing the decommissioning of plant prior to planned maintenance
  • Process governing the commissioning of plant following planned maintenance
  • Process dealing with the actions required in the event of equipment malfunction
  • Maintenance logs which record both the preventive and corrective maintenance work carried out

In a service environment if there is any equipment upon which the capability of your service depends, this equipment should be maintained. Maintenance may often be sub-contracted to specialists but nevertheless needs to be under your control. If you are able to maintain process capability by bringing in spare equipment or using other available equipment, your maintenance procedures can be simple. You merely need to ensure you have an operational spare at all times. Where this is not possible you can still rely on the call-out service if you can be assured that the anticipated downtime will not reduce your capability below that which you have been contracted to maintain. The requirement does not mean that you need to validate all your word-processing soft- ware or any other special aids you use. Maintenance means retaining in an operational condition and you can do this by following some simple rules.

  • A Planned maintenance is maintenance carried out with forethought as to what is to be checked, adjusted, replaced, etc.
  • Preventive maintenance is maintenance carried out at predetermined intervals to reduce the probability of failure or performance degradation. An effective maintenance system should be one that achieves its objectives in minimizing downtime, i.e. the period of time in which the equipment is not in a condition to perform its function.
  • Corrective maintenance is maintenance carried out after a failure has occurred and is intended to restore an item to a state in which it can perform its required function.
  • Predictive maintenance is part of planned preventive maintenance. In order to determine the frequency of checks you need to predict when failure may occur. Will failure occur at some future time, after a certain number of operating hours, when being operated under certain conditions, or some other time? An example of predictive maintenance is vibration analysis. Sensors can be installed to monitor vibration and thus give a signal when normal vibration levels have been exceeded. This can signal tool wear and wear in other parts of the machine in advance of the stage where nonconforming product will be generated.

The manuals provided by the equipment manufacturers should indicate the recommended preventive maintenance tasks and the frequency they should be performed covering such aspects as cleaning, adjustments, lubrication, replacement of filters and seals, inspections for wear, corrosion, leakage, damage, etc. Another source of data is from your own operations. By monitoring and analyzing tool wear, corrective maintenance, cutting fluids, and incident reports from operators you can obtain a better picture of a machine’s performance and predict more accurately the frequency of checks, adjustments, and replacements. For this to be effective you need a reporting mechanism that causes operators to alert maintenance staff to situations where
suspect malfunctions are observed. In performing such monitoring you cannot wait until the end of the production run to verify whether the tools are still producing conforming product. If you do you will have no data to show when the tool started producing nonconforming product and will need to inspect the whole batch. An effective maintenance system depends upon it being adequately resourced. Maintenance resources include people with appropriate skills, replacement parts and materials, access to support from OEMs when needed, and the funds to purchase this material. If the equipment is no longer supported by the OEM, then you may need to cannibalize old machines or manufacture the parts yourself. This can be a problem since you may not have a new part from which to take measurements. At some point you need to decide whether it is more economical to maintain the old equipment than to buy new. Your inventory control system needs to account for equipment spares and to adjust spares holding based on usage. For the system to be effective there also has to be control of documentation, maintenance operations, equipment, and spare parts. Manuals for the equipment should be brought under document control. Tools and equipment used to maintain the operational equipment should be brought under calibration and verification control. Spare parts should be brought under identity control and the locations for the items brought under storage control. The maintenance operations should be controlled to the extent that maintenance staff should know what to do, know what they are doing, and be able to change their performance should the objectives and requirements not be met. Whilst the focus should be on preventive maintenance, one must not forget corrective maintenance. The maintenance crew should be able to respond to equipment failures promptly and restore equipment to full operational condition in minimum time. The function needs resourcing to meet both preventive and corrective demands since it is downtime that will have most impact on production schedules. The exact nature of the controls should be as appropriate to the item concerned, the emphasis being placed upon that which is necessary to minimize operational equipment downtime. It would be far better to produce separate procedures for these tasks rather than force fit the operational procedures to maintenance applications.

Clause Total productive maintenance

The organization must develop, implement, and maintain a documented total productive maintenance system.   TPM must include identification of process equipment necessary to produce conforming product at the required volume; availability of replacement parts for the equipment identified in item ;provision of resource for machine, equipment, and facility maintenance;packaging and preservation of equipment, tooling, and gauging;applicable customer-specific requirements;documented maintenance objective such as OEE (Overall Equipment Effectiveness), MTBF (Mean Time Between Failure), and MTTR (Mean Time To Repair), and Preventive Maintenance compliance metrics. Performance to the maintenance objectives shall form an input into management review. TPM system must regular review of maintenance plan and objectives and a documented action plan to address corrective actions where objectives are not achieved. It must also include the use of preventive maintenance methods and predictive maintenance methods, as applicable. Periodic overhaul should be part of TPM.

In the automotive industry, implementing a Total Productive Maintenance (TPM) system is vital for maximizing equipment efficiency, reducing downtime, and ensuring consistent product quality. TPM is a comprehensive maintenance approach that involves the entire workforce in maintaining and improving equipment, thereby optimizing overall production processesThe organization must Perform a FMEA on the various types of process equipment you use, to identify key process equipment to include in your program for planned total productive maintenance system. Consider doing this by equipment groups, if all equipment within a group operates in the same way. Identify maintenance as a process within your QMS , including any outsourced maintenance activities. Your planned maintenance program should include – schedule and timing; availability and training of personnel; types and scope of maintenance; records; tracking to maintenance objectives; use, storage and control of spare parts; control of any maintenance outsourcing; etc. There are many software programs available to help do this. Maintenance methods should include a review of manufacturer’s recommendations; storage; tool wear; optimization of up time; correlation of SPC data to maintenance activities; important characteristics of perishable tooling; fluid analysis; monitoring of circuits; and vibration analysis. Include, as appropriate, maintenance of equipment in your control plans. . Here are the key steps to develop, implement, and maintain a documented TPM system:

  1. TPM Policy and Strategy: Define a TPM policy and strategy that aligns with the organization’s goals and objectives. Clearly communicate the importance of TPM and its role in achieving operational excellence.
  2. TPM Team Formation: Establish a TPM team comprising representatives from various departments, including production, maintenance, engineering, and quality assurance. This cross-functional team will drive the implementation and continuous improvement of TPM practices.
  3. Baseline Assessment: Conduct a comprehensive assessment of the current maintenance practices and equipment conditions to identify areas for improvement. This assessment serves as a baseline for measuring TPM progress.
  4. TPM Pillars and Activities: Develop a structured TPM framework with the key pillars, which typically include Autonomous Maintenance, Planned Maintenance, Quality Maintenance, Education and Training, Early Equipment Management, and Safety and Health Management. Define specific TPM activities and routines for each pillar.
  5. Autonomous Maintenance (AM): Empower equipment operators to take ownership of basic maintenance tasks, such as cleaning, inspection, and minor adjustments. Provide training to operators to enhance their technical skills and maintenance awareness.
  6. Planned Maintenance (PM): Implement a proactive maintenance schedule based on the equipment’s condition and performance. Schedule routine inspections, preventive maintenance, and timely replacements of parts to avoid breakdowns.
  7. Quality Maintenance (QM): Integrate quality checks into the maintenance process to prevent defects and ensure that equipment operates within specified tolerances.
  8. Education and Training: Provide comprehensive training programs for all employees, including operators, maintenance personnel, and supervisors, to ensure everyone is well-equipped to contribute to the TPM initiatives.
  9. Early Equipment Management (EEM): Involve engineering and maintenance teams in the design and selection of new equipment to optimize reliability, maintainability, and ease of maintenance.
  10. Safety and Health Management: Prioritize safety practices and create a safe work environment. Ensure that TPM activities do not compromise the safety of employees or equipment.
  11. Documentation and Standardization: Document all TPM procedures, checklists, and best practices. Standardize maintenance routines to ensure consistency across shifts and teams.
  12. Performance Monitoring and Continuous Improvement: Implement Key Performance Indicators (KPIs) to monitor the effectiveness of TPM initiatives. Continuously review results, conduct root cause analyses for issues, and apply improvement methodologies like Kaizen to drive ongoing enhancements.
  13. Audits and Reviews: Conduct regular TPM audits and management reviews to assess compliance with TPM practices, identify areas for improvement, and ensure sustained commitment to TPM principles.

By developing, implementing, and maintaining a documented TPM system in the automotive industry, organizations can achieve higher equipment reliability, improved productivity, and enhanced product quality, contributing to their overall competitiveness and success.

Identification of process equipment

In a Total Productive Maintenance (TPM) system, identifying the process equipment necessary to produce conforming products at the required volume is a critical step in optimizing production efficiency and ensuring consistent quality output. This identification process involves thoroughly understanding the production requirements, capacity constraints, and the capabilities of existing equipment. Here’s how this aspect of TPM can be addressed:Firstly, the organization must conduct a comprehensive analysis of its production processes and product requirements. This includes understanding the production volumes, product specifications, and customer demands. By knowing the required volume and product attributes, the organization can determine the production capacity needed to meet market demands.Next, the organization should assess the existing process equipment to determine its suitability for meeting the required production volume and product quality. This evaluation involves considering factors such as equipment capacity, reliability, efficiency, and maintenance history. By identifying potential bottlenecks or inefficiencies in the current equipment, the organization can prioritize improvements and upgrades to enhance overall productivity.In cases where the existing equipment falls short of meeting the production requirements, the organization may need to invest in new machinery or technology. The identification of necessary process equipment involves considering the specific requirements of the product and production process. This may involve selecting equipment with higher capacity, improved automation, or enhanced flexibility to handle varying product specifications.Additionally, the organization should evaluate the potential risks associated with equipment failures and breakdowns. Implementing preventive maintenance practices and spare parts management becomes crucial to minimize downtime and ensure continuous production.Another essential consideration is training and skill development for operators and maintenance personnel. Employees must be trained to effectively operate and maintain the identified process equipment. This includes understanding the equipment’s functionalities, safety procedures, troubleshooting techniques, and efficient maintenance practices.Furthermore, documenting the identified process equipment and its capabilities is crucial for maintaining transparency and facilitating effective communication across departments. The documentation should include equipment specifications, maintenance schedules, performance metrics, and any relevant historical data. Such documentation aids in tracking the equipment’s performance over time and informs decisions related to equipment replacement or upgrades. By thoroughly analyzing production requirements, evaluating existing equipment, investing in necessary upgrades, and providing appropriate training, organizations can optimize their production processes and achieve high-quality, efficient, and cost-effective manufacturing operations.

Availability of replacement parts for the equipment

Absolutely, ensuring the availability of replacement parts for the equipment is a crucial aspect of Total Productive Maintenance (TPM). TPM aims to maximize equipment efficiency, minimize downtime, and optimize overall production processes. Availability of replacement parts plays a significant role in achieving these objectives. Here’s why it is important:

  1. Minimizing Downtime: Unplanned equipment breakdowns can lead to significant downtime, disrupting production schedules and affecting product delivery timelines. Having readily available replacement parts allows for quicker repairs, reducing downtime and minimizing production disruptions.
  2. Improving Equipment Reliability: The availability of replacement parts helps to maintain equipment in good working condition. Regular maintenance and timely replacement of worn-out parts contribute to improved equipment reliability and longevity.
  3. Reducing Inventory Costs: While it is essential to have replacement parts on hand, having too many parts in stock can tie up capital and increase inventory costs. TPM involves a balance between having enough spare parts available without excessive stockpiling.
  4. Supporting Preventive Maintenance: TPM emphasizes proactive maintenance practices to prevent equipment failures. Having replacement parts readily available facilitates the execution of preventive maintenance tasks on schedule, reducing the likelihood of unexpected breakdowns.
  5. Ensuring Consistent Quality: In the automotive industry, maintaining consistent product quality is crucial. Equipment in good working condition, with readily available replacement parts, contributes to producing conforming products and meeting customer requirements.
  6. Vendor Management: TPM involves managing relationships with equipment suppliers and vendors to ensure the timely availability of replacement parts. Good communication and coordination with vendors are essential for maintaining a smooth supply chain.
  7. Rapid Response to Equipment Failures: When equipment failures do occur, having replacement parts available allows maintenance teams to respond quickly. Quick repairs help avoid cascading equipment failures and further production disruptions.
  8. Critical Spare Parts Identification: For high-value or critical equipment, TPM includes identifying critical spare parts that may have longer lead times or unique sourcing requirements. This allows the organization to plan for potential contingencies in advance.
  9. Root Cause Analysis: Availability of replacement parts supports root cause analysis of equipment failures. Analyzing the failed parts can help identify underlying issues and guide continuous improvement efforts to prevent future failures.
  10. Employee Morale: Efficient equipment maintenance and timely repairs contribute to a positive work environment and boost employee morale. Employees are more likely to be motivated and engaged when they have the tools and resources necessary to do their jobs effectively.

In conclusion, the availability of replacement parts is a fundamental component of Total Productive Maintenance. It enables organizations to reduce downtime, improve equipment reliability, maintain consistent product quality, and support proactive maintenance practices. By managing replacement parts effectively, automotive companies can optimize equipment performance, reduce production disruptions, and enhance overall productivity.

Provision of resource for machine, equipment, and facility maintenance

the provision of resources for machine, equipment, and facility maintenance is a fundamental aspect of Total Productive Maintenance (TPM). TPM is a comprehensive approach that involves the entire workforce in maintaining and improving equipment to achieve operational excellence and enhance overall production processes. The availability of adequate resources is essential for successful TPM implementation. Here’s why it is crucial:

  1. Skilled Workforce: TPM requires a skilled and trained workforce that can effectively perform maintenance tasks. Provisioning resources for training and skill development ensures that employees have the necessary knowledge and expertise to maintain the equipment properly.
  2. Maintenance Tools and Equipment: To carry out maintenance tasks efficiently, the organization needs to provide the necessary tools and equipment. This includes tools for inspection, lubrication, calibration, and repair.
  3. Spare Parts and Inventory Management: Ensuring an adequate supply of spare parts is vital for timely repairs and preventive maintenance. Proper inventory management helps balance the availability of spare parts without excessive stockpiling.
  4. Preventive Maintenance Schedule: TPM emphasizes preventive maintenance to avoid unexpected breakdowns. Provisioning resources for implementing a preventive maintenance schedule enables regular inspections and maintenance tasks.
  5. Predictive Maintenance Technologies: Utilizing predictive maintenance technologies, such as condition monitoring and predictive analytics, can help identify potential equipment issues before they lead to failures. Provisioning resources for such technologies enhances equipment reliability and minimizes unplanned downtime.
  6. Maintenance Personnel: Allocating sufficient personnel dedicated to maintenance activities ensures that maintenance tasks are given priority and are promptly addressed when needed.
  7. Facility Maintenance: Apart from equipment maintenance, TPM also includes facility maintenance to ensure a safe and productive work environment. Resources must be provided for maintaining facilities, utilities, and infrastructure.
  8. Management Support: Provisioning resources for TPM implementation requires support from management. Adequate budget allocation, time allocation, and commitment from management are essential for successful TPM initiatives.
  9. Data and Information Systems: Effective TPM relies on data-driven decision-making. Provisioning resources for data collection, analysis, and information systems facilitates informed maintenance decisions and continuous improvement efforts.
  10. Continuous Improvement Initiatives: TPM is not a one-time activity but a continuous improvement process. Provisioning resources for TPM activities, such as Kaizen events and improvement projects, helps drive ongoing enhancements in maintenance practices and equipment performance.

By providing the necessary resources for machine, equipment, and facility maintenance, organizations can foster a culture of proactive maintenance, reduce downtime, improve equipment reliability, and enhance overall productivity. The commitment to resource provision reflects the organization’s dedication to TPM principles and its efforts to achieve sustainable improvement in maintenance practices and production efficiency.

Packaging and preservation of equipment, tooling, and gauging

Total Productive Maintenance (TPM) encompasses not only the maintenance of production equipment but also extends to the proper packaging and preservation of equipment, tooling, and gauging when they are not in use. This aspect of TPM is essential to ensure the longevity and optimal performance of these assets during periods of non-production or when they are not actively utilized. Here’s why packaging and preservation are important in TPM:

  1. Protection from Environmental Factors: Proper packaging and preservation shield equipment, tooling, and gauging from environmental factors such as dust, humidity, temperature fluctuations, and corrosive agents. This protection helps prevent deterioration and extends the equipment’s lifespan.
  2. Prevention of Damage: Adequate packaging prevents accidental damage during handling, transportation, and storage. It ensures that critical components, delicate parts, and precision gauges remain intact and free from physical harm.
  3. Optimal Calibration and Accuracy: Precise gauges and measuring instruments need to be well-preserved to retain their calibration and accuracy. Proper packaging prevents misalignment or damage that could affect their measuring capabilities.
  4. Reduction of Downtime: If equipment, tooling, or gauging is not adequately protected during idle periods, it may require additional maintenance or repairs before reuse. Proper packaging and preservation reduce downtime and improve the efficiency of resuming production.
  5. Cost-Effectiveness: Effective preservation practices lead to cost savings by prolonging the lifespan of equipment and reducing the need for frequent replacements or repairs.
  6. Preparation for Use: Well-preserved equipment, tooling, and gauging are ready for use when needed, eliminating delays caused by preparation and ensuring smooth workflow during production restarts.
  7. Standardization and Organization: Implementing standardized packaging and preservation practices ensures consistency across the organization. It also facilitates easy identification and retrieval of assets when required.
  8. Preservation of Critical Knowledge: Packaging and preservation practices help preserve critical knowledge about the handling and maintenance of equipment and gauging. This knowledge continuity is essential for maintaining operational efficiency over time, especially if there are changes in personnel or shifts.
  9. Compliance with Quality Standards: Effective preservation practices help organizations comply with quality management systems and regulatory requirements, which often mandate proper storage and handling of equipment and gauging.
  10. Sustainability and Environmental Impact: Proper preservation reduces the risk of equipment becoming unusable due to damage, thereby contributing to sustainability efforts by reducing waste and unnecessary replacements.

By incorporating packaging and preservation practices into the TPM system, organizations can ensure the longevity, reliability, and availability of critical assets. This proactive approach to asset management enhances the overall effectiveness of TPM and supports continuous improvement efforts in the manufacturing process.

Use of preventive maintenance methods

In the Total Productive Maintenance (TPM) system, preventive maintenance methods play a central role in optimizing equipment reliability, reducing downtime, and improving overall production efficiency. Preventive maintenance is a proactive approach that involves regularly scheduled inspections, maintenance tasks, and replacements to prevent equipment failures and unexpected breakdowns. Here’s how preventive maintenance methods are utilized in the TPM system:

  1. Scheduled Maintenance: TPM incorporates a well-defined schedule for preventive maintenance activities. This schedule is based on equipment condition, usage, and manufacturer’s recommendations. Regular inspections, lubrication, adjustments, and replacements are performed at planned intervals to ensure the equipment operates at peak performance.
  2. Condition-Based Maintenance: TPM utilizes condition monitoring techniques to assess the real-time health of equipment. Sensors and monitoring systems are used to track various parameters, such as temperature, vibration, and pressure. Based on these measurements, maintenance teams can identify early signs of potential issues and take corrective actions before failures occur.
  3. Standardized Maintenance Procedures: TPM emphasizes standardized maintenance procedures for all equipment. By developing detailed maintenance checklists and guidelines, organizations ensure that preventive maintenance tasks are consistently performed and that no critical steps are missed during the process.
  4. Autonomous Maintenance: TPM encourages equipment operators to actively participate in maintenance tasks. Operators are trained and empowered to perform routine inspections, cleaning, and basic maintenance tasks as part of the autonomous maintenance pillar. This decentralized approach helps in early detection of potential issues and reduces the burden on maintenance teams.
  5. Root Cause Analysis: When preventive maintenance tasks identify abnormalities or deviations, TPM incorporates root cause analysis to determine the underlying reasons. Addressing root causes helps prevent the recurrence of issues and fosters a culture of continuous improvement.
  6. Predictive Maintenance: TPM leverages predictive maintenance methods, which involve the use of advanced technologies and analytics to predict equipment failures. By analyzing historical data and trends, organizations can forecast when maintenance activities should be performed based on the equipment’s condition.
  7. Collaboration and Communication: TPM emphasizes collaboration between maintenance teams, operators, and production personnel. Effective communication channels facilitate sharing insights about equipment performance, allowing for timely preventive maintenance actions.
  8. Performance Metrics and KPIs: TPM employs performance metrics and Key Performance Indicators (KPIs) to measure the effectiveness of preventive maintenance efforts. KPIs such as Mean Time Between Failures (MTBF) and Mean Time To Repair (MTTR) provide valuable insights into equipment reliability and maintenance efficiency.
  9. Continuous Improvement: Preventive maintenance is subject to continuous improvement in the TPM system. Regular review and analysis of maintenance data, lessons learned from breakdowns, and feedback from operators lead to ongoing refinements in the preventive maintenance program.

By incorporating preventive maintenance methods in the TPM system, organizations can achieve higher equipment reliability, reduced downtime, enhanced product quality, and increased overall productivity. This proactive maintenance approach helps organizations move away from a reactive mode of maintenance and fosters a culture of continuous improvement and equipment care.

Use of predictive maintenance methods

In Total Productive Maintenance (TPM), the use of predictive maintenance methods is a proactive approach to anticipate and prevent equipment failures before they occur. Predictive maintenance leverages advanced technologies, data analysis, and condition monitoring to assess the real-time health of equipment. By predicting potential issues, organizations can schedule maintenance activities more efficiently, reduce downtime, and improve overall equipment reliability. Here’s how predictive maintenance methods are utilized in the TPM system:

  1. Condition Monitoring Techniques: TPM implements various condition monitoring techniques, such as vibration analysis, thermography, oil analysis, and acoustic monitoring. These methods continuously collect data on the equipment’s operating condition, helping identify early signs of potential failures or abnormalities.
  2. Real-Time Data Collection: Advanced sensors and monitoring systems are used to collect real-time data from the equipment during operation. The data is then analyzed to detect deviations from normal operating parameters, indicating possible equipment deterioration.
  3. Data Analytics and AI: TPM employs data analytics and artificial intelligence (AI) algorithms to process and analyze the collected data. Machine learning models can be trained to detect patterns and trends, enabling predictive capabilities to forecast equipment performance.
  4. Failure Prediction: Predictive maintenance methods assess the condition of critical components and predict the remaining useful life of equipment. This allows maintenance teams to schedule maintenance activities at the optimal time, avoiding unplanned breakdowns.
  5. Prognostics and Health Management (PHM): TPM integrates PHM techniques to monitor the overall health of equipment. PHM involves assessing the cumulative impact of various equipment conditions to predict potential failures.
  6. Predictive Maintenance Scheduling: Based on the insights provided by predictive maintenance methods, organizations can schedule maintenance activities during planned production downtime or at times that minimize disruption to operations.
  7. Cost Optimization: Predictive maintenance enables cost optimization by avoiding premature replacements of parts and reducing the need for unnecessary maintenance. It allows organizations to replace components only when they are approaching the end of their useful life.
  8. Reduced Maintenance Inventory: Predictive maintenance minimizes the need for carrying excess inventory of spare parts. Parts can be procured based on actual equipment health and maintenance requirements, reducing inventory costs.
  9. Reliability-Centered Maintenance (RCM): TPM incorporates RCM principles to identify critical components and prioritize predictive maintenance efforts based on their impact on overall equipment reliability.
  10. Continuous Improvement: Like other aspects of TPM, the use of predictive maintenance methods is subject to continuous improvement. Organizations can refine their predictive models, enhance data analytics capabilities, and expand the scope of condition monitoring to cover more equipment over time.

By integrating predictive maintenance methods into the TPM system, organizations can move from a reactive maintenance approach to a proactive and data-driven strategy. This shift results in increased equipment uptime, improved product quality, reduced maintenance costs, and enhanced overall operational efficiency. Predictive maintenance aligns with the core principles of TPM, empowering organizations to optimize their maintenance practices and achieve higher levels of equipment reliability and performance.

Periodic overhaul

In Total Productive Maintenance (TPM), periodic overhaul is a maintenance strategy that involves comprehensive and planned inspections, repairs, and refurbishment of equipment and machinery to restore them to like-new condition. It is a proactive approach to ensure that equipment continues to operate efficiently and reliably over extended periods. Periodic overhaul is often scheduled based on equipment usage, operating hours, or the manufacturer’s recommendations. Here’s how periodic overhaul fits into the TPM system:

  1. Inspection and Assessment: Before a periodic overhaul, the equipment undergoes a thorough inspection and assessment. This evaluation helps identify wear and tear, potential issues, and components that require replacement or refurbishment.
  2. Scope of Work: Based on the inspection results, the scope of work for the periodic overhaul is defined. It includes a detailed list of tasks, such as replacement of worn-out parts, refurbishment of critical components, and any necessary repairs.
  3. Scheduling and Planning: The periodic overhaul is scheduled during planned production downtime or when the equipment’s workload is relatively low. Proper planning ensures that the overhaul process is executed efficiently and minimizes disruptions to production.
  4. Dismantling and Refurbishment: During the periodic overhaul, the equipment is dismantled, and the identified components are refurbished or replaced. This may involve cleaning, reassembly, calibration, and testing of critical parts.
  5. Preventive Maintenance Integration: While conducting the overhaul, preventive maintenance tasks, such as lubrication, inspections, and adjustments, are incorporated to extend the equipment’s service life and improve reliability.
  6. Upgrades and Modifications: Periodic overhaul also presents an opportunity to implement upgrades or modifications that can enhance equipment performance, productivity, and safety.
  7. Documentation and Data Recording: Throughout the overhaul process, detailed documentation and data recording are maintained. This information serves as a historical record of the overhaul and helps track equipment health and performance over time.
  8. Performance Verification: After the overhaul, the equipment undergoes performance verification tests to ensure that it meets the required specifications and operates as expected.
  9. Training and Skill Development: TPM emphasizes the importance of skilled personnel in equipment maintenance. During the overhaul, training and skill development opportunities may be provided to maintenance teams to enhance their knowledge and capabilities.
  10. Continuous Improvement: Insights gained from the periodic overhaul are valuable for continuous improvement efforts. Any identified areas for improvement or modifications needed to enhance equipment performance are incorporated into the TPM system.

By including periodic overhaul as part of the TPM system, organizations can extend the service life of equipment, reduce the likelihood of unexpected breakdowns, and improve equipment reliability and overall productivity. A well-executed periodic overhaul ensures that equipment remains in optimal condition and continues to contribute to the organization’s efficiency and success.

Documented Maintenance objective

In Total Productive Maintenance (TPM), maintaining proper documentation of maintenance objectives and metrics is essential for effective management and continuous improvement of equipment maintenance practices. The documentation provides a clear understanding of performance, highlights areas for improvement, and facilitates data-driven decision-making. Here are the key maintenance objectives and metrics commonly documented in TPM:

  1. Overall Equipment Effectiveness (OEE): OEE is a critical metric used to assess the efficiency and performance of equipment. It measures the equipment’s availability, performance, and quality. OEE is calculated as the product of three factors: Availability (actual production time as a percentage of scheduled production time), Performance (actual production speed as a percentage of maximum speed), and Quality (good output as a percentage of total output). Documenting OEE data helps identify production losses, optimize equipment utilization, and prioritize improvement efforts.
  2. Mean Time Between Failure (MTBF): MTBF is the average time between two consecutive failures of equipment. It is a key reliability metric that indicates how long an asset can operate before experiencing a failure. Documenting MTBF data over time helps identify trends in equipment reliability and guides decisions related to maintenance planning, spare parts inventory, and replacement schedules.
  3. Mean Time To Repair (MTTR): MTTR measures the average time taken to repair equipment after a failure occurs. It is a critical metric to assess maintenance efficiency and how quickly equipment can be brought back into operation after downtime. Documenting MTTR data helps identify opportunities for reducing downtime and improving maintenance practices.
  4. Preventive Maintenance Compliance: TPM emphasizes the importance of preventive maintenance to avoid unexpected breakdowns. Documenting preventive maintenance compliance tracks whether scheduled maintenance tasks are being performed on time and according to the established procedures. It helps ensure that equipment is maintained proactively, reducing the likelihood of failures and optimizing equipment reliability.
  5. Maintenance Task Completion Rate: This metric tracks the completion rate of planned maintenance tasks. It indicates the effectiveness of the maintenance team in executing scheduled activities, such as inspections, lubrication, and adjustments. Documenting task completion rates helps identify any gaps or inconsistencies in maintenance practices.
  6. Downtime Analysis: Documenting the duration and reasons for downtime events provides valuable insights into the root causes of equipment failures. This analysis guides efforts to address recurrent issues, improve maintenance processes, and optimize equipment uptime.
  7. Equipment History and Work Order Records: Detailed documentation of equipment history, work orders, and maintenance activities provides a comprehensive view of the equipment’s performance over time. This historical data helps identify patterns, evaluate past maintenance interventions, and make data-driven decisions.
  8. Continuous Improvement Initiatives: Documenting improvement initiatives, including Kaizen events and other improvement projects, tracks the progress and results of efforts to enhance equipment reliability and maintenance efficiency.

By documenting these maintenance objectives and metrics in TPM, organizations can measure performance, identify areas for improvement, and establish a culture of data-driven decision-making. Regular review and analysis of the documented data enable continuous improvement efforts, helping organizations achieve higher equipment efficiency, reliability, and overall productivity.

Review of Maintenance plan and objectives

Regular review of maintenance plans and objectives is a crucial aspect of effective Total Productive Maintenance (TPM) implementation. By periodically evaluating performance against set targets and objectives, organizations can identify areas of improvement and take corrective actions to ensure continuous progress. Here’s how the regular review process and the documentation of corrective action plans are carried out in TPM:

  1. Frequency of Review: Maintenance plans and objectives are reviewed periodically, depending on the organization’s needs and the complexity of the maintenance processes. Common review frequencies include monthly, quarterly, or semi-annually.
  2. Performance Data Collection: To facilitate the review process, organizations collect and compile relevant performance data. This data includes metrics such as OEE, MTBF, MTTR, preventive maintenance compliance, task completion rates, and downtime analysis.
  3. Comparing Actual Performance with Objectives: During the review, actual performance data is compared with the predetermined maintenance objectives and targets. This comparison highlights any gaps between expected results and actual achievements.
  4. Root Cause Analysis: If objectives are not met, a root cause analysis is conducted to identify the underlying reasons for the shortfalls. Root cause analysis involves examining factors such as equipment malfunctions, maintenance delays, skill gaps, or changes in production demands.
  5. Corrective Action Plan Development: Based on the findings of the root cause analysis, a corrective action plan is developed to address the identified issues and improve maintenance performance. The action plan outlines specific steps, responsibilities, and timelines for implementing corrective measures.
  6. Clear Responsibilities and Accountability: The action plan clearly defines the responsibilities of individuals or teams assigned to execute the corrective actions. Assigning accountability ensures that corrective measures are implemented effectively.
  7. Resource Allocation: Adequate resources, including manpower, training, tools, and spare parts, are allocated to support the implementation of the corrective action plan.
  8. Monitoring and Progress Tracking: Progress towards achieving the corrective action plan is closely monitored. Regular follow-ups ensure that the planned actions are being executed as scheduled and that they are producing the intended results.
  9. Continuous Improvement Culture: The review process is an opportunity to foster a culture of continuous improvement within the organization. Lessons learned from corrective actions are used to drive ongoing refinements in maintenance practices and performance.
  10. Documentation: All review findings, corrective action plans, and progress updates are documented systematically. Documentation serves as a reference for future reviews, enables knowledge sharing, and helps track the evolution of maintenance practices over time.

By conducting regular reviews and documenting action plans to address corrective actions, organizations can ensure that TPM objectives are on track and aligned with broader business goals. The review process enables organizations to identify and address maintenance challenges promptly, optimize equipment performance, and continually improve maintenance practices to achieve higher levels of productivity and efficiency.

Applicable customer-specific requirements

In Total Productive Maintenance (TPM), customer-specific requirements refer to the specific expectations and standards set by a customer regarding the maintenance of equipment and machinery used in the production process. These requirements may vary from one customer to another based on their industry, product specifications, quality standards, and any other unique considerations. Here are some examples of applicable customer-specific requirements in TPM:

  1. Maintenance Schedule and Downtime Planning: Some customers may have strict production schedules or specific times when they cannot afford downtime. In TPM, maintenance planning must align with these customer requirements to minimize disruptions to their production and ensure timely deliveries.
  2. Equipment Performance Metrics: Certain customers may request specific equipment performance metrics, such as OEE, MTBF, or MTTR, to ensure that the machinery meets their productivity and reliability standards. TPM must incorporate the tracking and reporting of these metrics as per the customer’s requirements.
  3. Maintenance Documentation and Reporting: Customers may require detailed maintenance documentation and regular reports on the maintenance activities performed on their equipment. TPM should ensure accurate and comprehensive record-keeping to fulfill these requirements.
  4. Preventive Maintenance Practices: Some customers may have specific preventive maintenance practices they expect suppliers to follow to maintain equipment in peak condition. TPM must incorporate these practices into the maintenance plan and ensure compliance.
  5. Safety and Environmental Standards: Customers may have specific safety and environmental standards that apply to maintenance activities. TPM should ensure that maintenance procedures and practices comply with these requirements to maintain a safe and environmentally responsible work environment.
  6. Equipment Calibration and Accuracy: For customers in industries with high precision requirements, TPM should ensure that equipment calibration and accuracy are maintained to meet the customer’s specifications.
  7. Spare Parts Inventory Management: Some customers may have specific requirements regarding spare parts inventory levels and management. TPM should align spare parts inventory practices with the customer’s needs to avoid delays and disruptions in case of equipment failures.
  8. Continuous Improvement Initiatives: Some customers may expect TPM to include continuous improvement initiatives aimed at enhancing equipment performance and efficiency over time. Regular updates on improvement projects and their impact may be required.
  9. Maintenance Skill Requirements: Customers may have specific expectations regarding the skill level and training of maintenance personnel. TPM should address these requirements by providing relevant training and ensuring that the maintenance team possesses the necessary competencies.
  10. Communication and Collaboration: Effective communication and collaboration with customers are essential in TPM. Regular updates, open communication channels, and responsiveness to customer inquiries or feedback are vital to meeting customer-specific requirements.

It’s important for organizations implementing TPM to thoroughly understand and incorporate these customer-specific requirements into their maintenance practices. Adhering to these requirements not only helps meet customer expectations but also fosters stronger relationships with customers, leading to enhanced customer satisfaction and long-term business success.

Leave a Reply