When we realize that in many factories, the valuable operating time is less than 50% of the gross available hours per year, it is obvious that our assets are not sweating. Part of this is caused by scheduled downtime, which includes holidays, no production planned due to limited load, spare capacity to cope with volume flexibility etc. The other part is caused by the fact that we do not produce fully efficiently. The reasons for this can be categorized into six big losses. These losses can be influenced during development and production.
Although the name sounds very technical, the original Japanese characters mean "Total People Participation". TPM encourages operators to take ownership of their machines and to involve them in improvement activities.
TPM is an industrial standard and it is an approach to optimize the effectiveness of production means in a structured manner.
TPM focusses on improving the Planned Loading Time. The gap (losses) between 100% and actual efficiency can be categorized into 3 categories:
- Yield (Quality Rate)
Breakdowns and changeovers indicate situations where the line is not running while it should be.
Speed losses and small stops/idling/empty positions indicate the line is running, but is not providing the quantity it should.
Additionally, when the line producing products, there are losses due to rejects and start-up quality losses.
These losses lead to the Overall Equipment Effectiveness (OEE) indicator, which tells you how efficiently you produce when you have planned to produce. TPM helps you to improve your OEE by providing a structure to quantify these losses, and by subsequently giving priority to the most important ones. TPM provides concepts and tools to achieve both short and longer term improvements.