Page 197 - DMGT524_TOTAL_QUALITY_MANAGEMENT

Total Quality Management

Notes Step 9: Develop a planned or preventive maintenance program: Create a schedule for
preventive maintenance on each piece of equipment.
Step 10: Conduct training to improve operation and maintenance skills: Maintenance
department will take on the role of teachers and guides to provide training, advice, and
equipment information to the teams.

Step 11: Develop an early equipment management program: Apply preventive
maintenance principles during the design process of equipment.
Step 12: Continuous Improvement: As in any Lean initiative the organization needs to
develop a continuous improvement mindset.
Maintenance and reliability as a core business strategy is the key to a successful TPM
implementation. Without the support of top management, TPM will be just another
“flavour of the month.” Implementing TPM using the above 12 steps will start you on the
road to “zero breakdowns” and “zero defects.”

13.2.4 Identifying Improvement Needs

People at the operational level can throw better light on needs of improvements. Maintenance
technicians have better knowledge about which machines are on the verge of breakdown, which
machines need more attention for maintenance activities. Hence employees who work with
machines on their day-to-day work are better capable of identifying the improvement needs
than any other employees. Therefore involvement of operators and maintenance technicians is
very important in identifying improvement needs. Opinion of these employees on which systems
and machines need more urgent attention has to be taken into consideration. This may need
constitution of an implementation team consisting of production operators and maintenance
technicians.

The teams constituted should focus on current level performance and this can be done in the
form of assessment existing systems. Japanese TPM practitioners have developed following
measurements for identifying improvement needs. These measurements are six major areas of
losses so that how improvements can reduce them. They are listed below:

Down Time Losses

1. Planned
(a) Start-ups
(b) Shift changes

(c) Coffee and lunch breaks
(d) Planned maintenance shut downs
2. Unplanned Downtimes
(a) Equipment breakdown

(b) Changeovers
(c) Lack of materials

Reduced Speed Losses

3. Idling and minor stoppages
4. Slow-downs

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