Professional Documents
Culture Documents
Pillar in TPM
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→ In some cases, operators run machines until they get breakdown at that time
organization lost productivity, and also it will take time for machine repair and
maintenance.
→ All team members should be given basic training on TPM and why we need to
implement it.
→ The skill level of team members to be defined and the implementation plan should
be shared with the team members.
→ But the effective use of machines is also important while we are operating
machines.
→ For this, we need to train the operator on the technical details of the machine and
its various components, its functions, and their purpose, as well as Problem-Solving,
and troubleshooting skills.
➨ In very easy language, operators should have below four minimum skills that are
related to machine
→ So, to improve the skills of operators we need to give training and evaluate them
on machines with the help of actual task offering.
→ The purpose of the initial cleaning is to identify the various abnormalities (Fuguai)
during the cleaning activity.
→ This step is towards the equipment get back to almost a Brand New Condition
with the help of overhauling and machine and surround area cleaning activity.
→ All team members (like - production, maintenance, engineering, operator, etc.)
should be available during this activity.
→ The goal of initial machine cleaning and inspection activity is to fully restore each
piece of machine to its full performance by identifying and eliminating the
deterioration.
→ It's better to have proper documentation for this activity so we can have
traceability of progress.
⇢ Inaccessible Places.
⇢ Contamination Sources.
⇢ Unsafe Places.
Step 02. Eliminating the SOC (Source of Contamination) and Improve HTA
(Hard to Access):
→ The purpose of the second step is to eliminate the sources of contamination and
improve the access of hard-to-access areas with the help of implementing
various Kaizens.
→ In the 1st step we have completed the initial cleaning, so we have equipment in
brand new condition.
→ For this, we need to focus on the elimination of the cause of contamination and
improving the cleaning and maintenance accessibility.
→ For this step, we need to consider safety as a priority due to the machine is in
running condition.
→ So we can easily able to visualize the rotating parts are working ok or not.
⇢ Promoting Orderliness means making sure that all tools have their own place
and we need to put them in their defined place.
⇢ Promoting the safe working practices - use lockout/tag-out (LOTO) during the
cleaning or performing the task if operators having a risk of injury for reach
contamination areas
→ The purpose of this step is to develop the tentative standard for maintaining
machine conditions as we have achieved in steps 1 and 2.
→ The standard should clearly define which component of the machine should be
cleaned and lubricated by whom, when, and how.
⇢ Also, include if any other critical task is suggested by the maintenance team
during this activity
→ Once the standard is finalized then it should be easily available to all operators.
→ As we know that the steps 1 to 3 are preventing the equipment from force
deterioration.
→ In this step, the team members should be trained on the inspection manual and
they are also able to identify the slight defects and machine restoration.
→ In this step, we need to reduce the number of checks specified in the cleaning,
lubricating, and inspection standards.
→ We need to focus on reducing the inspection time with the help of implementing
visual management, and PokaYoke.
⇢ In the case of a belt, and chain drive we can provide the direction and
maximum and minimum slackness area during operating condition
→ Also, the operator can check the different mechanical problems such as cracks,
wear, and tear of various machine components, functions of different sensors.
→ Steps 1 to 5 are focus on maintaining the machine's basic conditions and daily
inspection.
→ The purpose of standardization is the reduce all kinds of losses and empower the
operator for maintenance and management of the equipment by standardizing the
activities and standards.
→ Visual Management means making visible all machine components and their
operating condition.
⇢ We can also apply the green and red colors for the normal and critical levels of
operation
→ Now the purpose of step 7 is to encourage the operator to drive and initiate the
improvement activities.
→ Now operators are the owner of the machine and they will also lead the
continuous improvement activities.
→ Displaying and sharing One Point Lessons to team members for any changes
→ Tracking and analyzing the equipment breakdown data - also implement the
actions on time
→ Monitor the machine component wear with the help of various techniques like oil
analysis, vibration analysis, and infrared thermography.
→ Apart from the above-mentioned points, you can work on different points as well
as per your process and machine.