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Total productive maintenance in the industry: how to plan?

Discover the benefits of adopting total productive maintenance and how to plan it in your industry.

Since World War II, there was a natural need to invest in new equipment for the industry. The main focus at this time was automation and process sophistication. Japan was one of the countries that immediately
invested in technology development. As such, it has become one of the world leaders in robot applications.

It is in this context that Total Productive Maintenance arises, also known as TPM. The term was originally defined by the Japanese Plant Maintenance Institute (JIPM). TPM is more than a set of rules that raise the quality and efficiency standard.

“Total Productive Maintenance helps to raise awareness of everyone in the company in search of excellence”, notes the commercial technical manager of Hexagon Manufacturing Intelligence of Brazil, Henrique Moreira.

Initially, the purpose included maximizing team effectiveness. That is, the development of a productive maintenance system that covers the life of the equipment and the participation of all employees. Then,
from top management to the workshop, everyone was part of the process.

Today, however, Total Productive Maintenance helps the industry in many ways. This assistance ranges from working on the continuous training of employees to focusing on efficiency through maintenance plans. In
this way, it is possible to provide an optimized work environment with highly evolved quality control methods.

Total Productive Maintenance Objectives

The main objective of TPM is to promote planned and scheduled maintenance. It’s based on human behavior and understands that greater availability, easy operation and maintenance of machinery and equipment
contribute to maintaining a productive and quality industrial environment. Within this methodology, there are three secondary objectives that deserve to be highlighted: zero ruptures, zero defects and zero accidents in companies.

Benefits of Total Productive Maintenance

According to Moreira, the benefits obtained from PMS are already quite visible in the short term. "For example, there is an improvement in the work environment due to the appreciation of employees with training," he says.

In general terms, these benefits can be divided into tangible and intangible. The tangible refers to the increase in net productivity, which ranges between 50% and 100%, and the plant, which accompanies the same percentage. Defects, in turn, can fall 90% and customer complaints will mean only 25%. In addition, it’s worth noting that production costs can be reduced by 30%.

Intangible benefits, on the other hand, are self-managed by employees. Operators take care of their own equipment without constant steering. In addition, they develop a clean and organized workplace, as well as
establish a self-confidence and a proactive attitude. This contributes significantly to reducing downtime and equipment defects.

How to plan?

Taking on a new management and work methodology also involves the company's organizational culture. Therefore, it’s not possible to change from night to morning. Awareness-raising and support is needed for changes involving all levels of hierarchy.

Everyone must understand the benefits that MPT will bring to the work routine and to the company and, therefore, participate in the implementation. Even so, managers must be able to map and design tasks and
processes assertively. In addition, they need to define appropriate indicators to measure the results.

It’s also common to implement committees made up of employees from all hierarchies. The idea is to generate ideas, improvements, report difficulties and disseminate policies and guidelines to employees
quickly and efficiently.