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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.
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Availability Losses
- breakdowns,
changeovers
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Performance Losses
- speed loss, minor stoppages
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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
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MCMT220A
Apply Quick Changeover Procedures
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MCMT250A
Monitor process capability
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MCMT251A Apply quality standards
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MCMT280A Undertake root cause analysis
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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
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TPM and OEE Improvement Resources
available from our resource centre include
TPM Resources
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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.
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OVERALL EQUIPMENT EFFECTIVENESS (OEE)
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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