Total Productive Maintenance
It is becoming increasingly difficult to ignore the fact that the contemporary heavy industry suffers from its obsession with records in performance. Doubtless, this evidence is mainly based on the constantly growing demands at the world markets, but it is pivotal to mention that attempt to produce more goods in a shorter period is not a sign of a satisfactory quality. Therefore, a need for a complex approach towards quality but rather quick manufacturing has emerged. The recent history of manufacturing, however, has proved that the majority of failures in quality can be referred to the exceeding use of the standard machinery. Thus, quality manufacture can be provided with machinery, which does not develop any faults. In such a way, Total Productive Maintenance has been designed in 70’s. Nowadays, this methodology is still applicable so that it is necessary to reveal its comprising components in order to identify its essence. Taking this point into account, it should be admitted that the following paper discusses the comprising elements of Total Productive Maintenance in terms of the contemporary manufacturing asset.
Asset Selection and Priority Ranking
To begin with, it is necessary to admit that the chosen asset is a recycling machine for accumulator batteries. The asset at the middle-sized manufacturing organization, which is oriented on recycling of led materials. In such a way, the asset is the initial unit within the chain of manufacture as long as it recycles damaged and broken accumulator batteries for the further utilizing in the process of manufacture. The organization serves various companies of heavy industry so that it has a constant flow of demands. Taking these points into consideration, the priority ranking consists of the following points. First of all, the analysis of raw material for the recycling is required. Proper balance between elements of raw material is pivotal in this industry as it influences the quality of products primarily. Therefore, any ordered material should be analysed in the lab environment initially. Second, it is necessary to provide a related framework, which is based on the results of the lab analysis of raw materials. The framework is directly addressed to the optimization of the entire asset via a considerable involvement of the personnel (Marquez 2007). Third, as a consequence, the framework should address the considerations of performance. The framework has to identify frequency of recycling rounds per a particular period in order to ensure quality, which is one of the objectives of Total Productive Maintenance. Fourth, is closely related to the framework, as well because it is a consideration of energy consumption, which is not important to the customers of the organization but is a valuable aspect for any firm, which performs in terms of TPM.
In fact, the calculation of OEE percentage is not empirically-driven metrics so that it is quite reasonable to characterize OEE of the asset from a practical perspective (Ade Asefeso MCIPS MBA 2014). In such a way, the initial OEE ranking of the asset was the following. The first place obtained performance as it is the main objective of any manufacturing organization. The second was quality, which is also an obvious concern of many manufacturers. The third was availability as the majority of manufacturers are particularly interested in quality and performance without any respect to the fact that these processes may become exceedingly complicated. In a similar manner, the recent developments suggest that the implementation of quick changeover is a practical decision. Changeover is an approach for the organizations, which regard the improvement as a constant process (Stamatis 2011). Therefore, this approach is quite applicable to the recycling asset as it performs in terms of TPM. Regarding the point that changeover approach minimizes inventories and increases flexibility of the machinery, it should be admitted that new OEE rating is a conversed version of the initial one. In other words, availability is on the first place, quality on the second, and the performance on the third.
Actions Employed to Improve OEE Ranking
The diagram below illustrates a so-called 4M’s approach, which include the following aspects. The first aspect is methods. As long as the OEE priority of the asset is availability, methods, which are applied to the machinery, have to be simplified. What is more, they are required to be sustainability-friendly because environmental considerations are one of the most alarming concerns nowadays. The second aspect is material. The main requirement to the material has been already outlined. In such a way, any raw materials are supposed to undergo lab experiments, which identify a certain proportion between them. The third aspect is machine. Needless to say, it should be able to perform according to the designed methods and be maximally easy regarding its daily usage. The fourth aspect is men. In particular, workers have to be trained sufficiently in order to provide the asset with three previous aspects because Total Productive Maintenance presupposes a meaningful involvement of human resource. Besides that, staff should follow a certain framework, which is also developed in terms of TPM. This requirement has been already issued in the previous section. Eventually, the personnel are required to work in cooperation as the outlined aspects need a simultaneous service.
Why It is necessary to be explicit about the approach, which has been illustrated in the diagram and previous subsection. First of all, the performance rates will be increased as the optimization takes less time in terms of quick changeover. The second reason is an obvious consideration of environmental concerns. As the 4M’s diagram suggests, the asset has to utilize sustainable methods of performance so that the operation of the machinery will be maximally environmentally-friendly. The machinery will produce less material as it will be utilized for improvement of the quality (Agustiady & Badiru 2013). What is more, the mobilization of the entire asset reinforcements is also reflected on the strategy of the entire strategy of a manufacturing company. It can be explained by the fact that TPM involves different aspects of the organization so that new ways of communication and management will be required at least partially. Besides that, new frameworks and strict guidelines, which are based on the objectives of TPM, will be associated with new ethical code because these rules also touch upon various aspects of the organization’s overall performance. As a consequence, the operating team will become more cooperative as it is the mean requirement to the human resource in terms of 4M fishbone diagram. Total Productive Maintenance cannot be applied to the asset in case the personnel do not coordinate their activities regarding the machinery and raw materials.
Actions for Autonomous and Planned Maintenance For starters, it is worth saying that autonomous maintenance should follow a certain framework, as well. Thus, it is essential to develop approximate scenarios for every single context of operating. In such a way, the asset will achieve a maximal flexibility regarding its autonomous activities, which do not depend on planning. Moreover, it is crucial to determine minimal and maximal parameters for the machinery. These parameters will be used for setting top and below margins for the outlined framework. The personnel should be aware of these margins as well because it is an additional orientation for keeping the asset performing with required parameters. As a consequence, security concerns should be also addressed. The main objective of TPM is a performance of the asset at the maximum of its capacity on a regular basis so that the machinery does not develop a fault. Regarding this point, TPM implies maximum of safety as equipment, which works properly cannot cause any emergency situation (Soares 2010). Besides that, it is abundantly important to consider a case of the asset’s low performance. Namely, in case the asset fails to operate with the required amount of material it has to follow certain guidelines for recovery of its normal performance. By the same token, exceeding fulfilment of plan should be also addressed because it usually implies overconsumption of energy and raw material.
As for planned maintenance, it is to be said that every single customer demand should meet certain requirements. In other words, there is no any common pattern for working with all instructions of the customers. Hence, planned maintenance should be as flexible as possible. In the same way, it is important to develop a plan for a particular period, which includes all demands within certain dates of the schedule. To the broadest extent, daily plan is also required. Daily plan is one of the main determinants of Total Productive Maintenance as a number of recycling rounds depends not only of technical peculiarities of the order but on the customers’ requirements, as well. Eventually, the personnel is supposed to set particular parameters for every single rounds because it is becoming increasingly apparent that thermal, mechanical, and electrical limits make an impact on the condition of the machinery and thus, quality of the manufacture (Kerszenbaum & Klempner 2004).
SMED for Planned Maintenance As the flexibility of the asset has been outlined as the one of the most important aspects of Total Productive Maintenance for the recycling asset, it is to be noted that in case the asset needs to change its planned parameters it will be expected to underpin them with a related analysis. Hence, SMED should include quick analysis of raw materials in order to create the basis for the amendments in the parameters. Still, it is highly recommended to provide alternative machinery, which is simultaneously optimized for potential changes in the manufacturing process. The main reason for the alternative machinery is based on the fact that it economizes on time and effort even though it is technically weaker than the primary asset. Therefore, it is desirable to develop potential scenarios in beforehand or at least their approximate sketches. It will decrease the time for changeover and make the changes more accurate regarding the desired effect. That is why these effects should be divided into several blocks of parameters (Henry 2013). In case the equipment allows to record these blocks as ready-to-go set-ups, they should be doubtlessly saved in the memory of the asset. Nobody would deny the fact that safety still has to remain central concern during the SMED process (Gopalakrishnan 2010). Thus, none of parameters, which exceed top and below margin of performance, should be included in planned patterns of maintenance. The asset should perform slower but with maximal guarantees of safety.
All in all, the study has discussed the comprising elements of Total Productive Maintenance in terms of the accumulator battery recycling asset. To be more exact, the paper has determined the asset and ranked its operations with the related priorities. Then, the paper has given an account to the OEE rating, which includes the initial layout of the priorities and the changed ones in terms of Total Productive Maintenance. As a consequence, the paper has discussed the main points regarding the actions concerning the asset. A fishbone 4M’s diagram has been developed in order to illustrate the main objectives of TPM in the context of the determined asset. By the same token, actions for autonomous and planned maintenance have been issued, as well. Eventually, SMED for the asses has been also suggested. To conclude, it is necessary to admit that Total Productive Maintenance should be associated with a safe and quality manufacturing rather than with a high performance and economy of time.
Ade Asefeso MCIPS MBA, 2014, TPM simplified, AA Global Sourcing, Ltd., Swindon.
Agusitady, T & Badiru, BB 2013, Sustainability: utilizing lean six sigma techniques, CRC Press, Boca Raton.
Gopalakrishnan, N 2010, Simplified lean manufacture, PHI Learning Private, Ltd., New Delhi.
Henry, JR 2013, Achieving lean changeover: putting SMED to work, CRC Press, Boca Raton.
Kerszenbaum, I & Klempner, G 2004, Operation and maintenance of large turbo-generators, John Wiley & Sons, Inc., Hoboken.
Marquez, AC, 2007, The maintenance management framework: models and methods for complex systems maintenance, Springer Science & Business Media, London.
Soares, CG 2010, Safety and reliability of industrial products, systems, and structures, CRC Press, Boca Raton.
Stamatis, DH 2011, The OEE primer: understanding overall equipment effectiveness, reliability, and maintainability, CRC Press, Boca Raton.