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Total Productive Maintenance Programs

Recognized as an industry standard, Total Productive Maintenance (TPM) is a system used to improve equipment performance.

TPM provides a complete framework for improving equipment capabilities, using a method known as Overall Equipment Effectiveness (OEE) to monitor equipment performance. OEE losses fall into the following categories.

  1. Availability Losses - breakdowns, changeovers

  2. Performance Losses - speed loss, minor stoppages

  3. Quality Losses - defects, rework and yield loss

We offer a range of TPM related programs including introductory training, an OEE improvement challenge, and maintenance excellence programs.

Many of our programs can be used to support a "Lean" or Competitive Manufacturing Program and may be eligible for funding.

Cert III in Competitive Manufacturing 

  • MCMT220A     Apply Quick Changeover Procedures

  • MCMT250A     Monitor process capability

  • MCMT251A     Apply quality standards

  • MCMT280A     Undertake root cause analysis

  • MCMT281A     Contribute to a proactive maintenance strategy

Cert IV in Competitive Manufacturing 

Diploma in Competitive Manufacturing 

To request an information sheet click here

To have a TPM Specialist contact you click here
 


TPM and OEE Improvement Resources
available from our resource centre include

TPM Resources
 

 


TOTAL PRODUCTIVE MAINTENANCE (TPM)                      

Often referred to as Total Productive Maintenance (TPM), a system originally developed by the Japanese Institute for Plant Maintenance (JIPM) TPM has become an internationally accepted program for improving plant capability.

Companies applying TPM programs have experienced significant improvement in plant performance and communications between operational and maintenance personnel.

In Australasia TPM programs are often referred to as “Equipment Care”, or "Proactive Maintenance" programs. These programs may be funded using the Competitive Manufacturing Training Program

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OVERALL EQUIPMENT EFFECTIVENESS (OEE)    

Overall Equipment Effectiveness is a measure of your plants performance. It combines the effects of lost time from availability losses, performance losses and quality losses.

It is an international standard for measuring plant and equipment performance and was developed by the Japanese Institute of Plant Maintenance (JIPM) in the early 1980’s. Many of our Manufacturing Excellence Coaches have been trained by the JIPM and used these principles in Australasia, US and the UK.

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AVAILABILITY LOSSES

Typical availability losses include breakdowns, lack of an operator, waiting on other equipment, material or approvals, unplanned meetings and changeover times.

Changeover times are included as many companies can significantly reduce the time required to change from one product run to another.

The Improve Group provides in-house workshops for quick changeovers. These can be funded if included in a Competitive Manufacturing Program. For more information click here

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PERFORMANCE LOSSES

 

Performance losses impact on the throughput capacity of the plant.

Key losses occur due to machines running at a slower rate than they were designed for – this often occurs when machines are poorly maintained, trainee operators are running the machine, or products have different characteristics – consistency, size, handling, temperature, viscosity, etc.

Minor stoppages often occur if equipment misaligns and requires re-adjustment, product jams in the handling systems, or equipment overheats and has to be reset.

Performance losses reduce the actual operating hours and the resultant is known as Net Operating Time.  

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QUALITY LOSSES                  

 

Operating time is reduced by quality losses – the time lost when producing defective product, start up losses and any reworked product.

Reworked product has a double effect as it uses time that could be used to make good product – once when it is first manufactured, and again when it is reworked. Often the rework time is longer than the original time taken to produce the product as the product needs to be reloaded and unloaded.

 

Quality Improvement and Six Sigma programs can make a significant difference to these losses. 

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