Impacts of Total Productive Maintenance

Topics: Total productive maintenance, Maintenance, Overall equipment effectiveness Pages: 12 (3482 words) Published: September 12, 2008

Total Productive Maintenance (TPM) is a conceptual approach which focuses at the maximization of effectiveness of different facilities within an organization. In its major role it helps us understand the relationships between the different organizational functions and in particularly between production and maintenance (Park and Han, 2001). As many companies around the world have implemented TPM and are successful and satisfied with the implementation; while there are many who are implementing it and gaining the advantage by its continues improvement. But there are some companies who have failed to gain advantage and some who are skeptic about its implementation. This leads us to know more about how TPM impacts different components of different organizations. This article focuses on some components such as overall effectiveness and cultural impacts of TPM on an organization. It concludes in building and maintaining a supportive culture and how overall effective helps in gaining a competitive edge over a long period of time.

Any organization want to chase in world class competition must give customer satisfaction by providing reliable product or service on time at lower prize then others. One of the premises is that good maintenance and plant engineering process gives fundamental success in manufacturing (Hanson, 1995; Madu 2000).So the organization must reduce the unnecessary cost of time and material by reducing maintenance cost. And to reduce the maintenance cost is one of the reason to develop manufacturing technology like TPM (total productive maintenance).TPM is introduced by Seiici Nakajima in late 1970s in Japan, which made major influence over the economic progress of Japanese manufacturers (Willmott, 1994).

TPM is basically a program to improve maintenance effectiveness of equipment throughout its life in the organization by the participation and motivation of all workforces from top management to the line employee from all department of an organization (Nakajima, 1988). The main goal of TPM to achieve maximum productivity with only limited investment in maintenance. This goal can be achieve by increase the overall equipment effectiveness(OEE) by reducing the losses, by improving existing maintenance system, by implementing autonomous maintenance and by increase a skill and motivation of operators from individual and group development (Willmott, 1994). And also by proper maintenance of equipment and facilities for best performance in order to reduce their life cycle cost. One of the properties of TPM is that production operators assist to repair the equipments when it is down and thus they share their effort in preventive maintenance and in turns improvement in process (Jostes & Helms. 1994)

In this term paper we focus on impacts of TPM. Many companies such Steelcase, Tennessee Eastman(Garwood, 1990), Nissan(Suzuki, 1993) adopted TPM are satisfied with the technique and find significant reduction in break down labor rates, lost of production, setup cost and cost per maintenance unit(Koelsch, 1993).TPM helps to planned and controlled the maintenance expanse(Adair-Heely, 1989) and reduction in maintenance force. For example a person who pays for preventive works are no more needed after implementing TPM, because TPM terns all activities of PM works to production forces. TPM gives opportunity to all individuals to express idea to improve the process and become a more familiar with tools and techniques to solve the problems and this effect directly to the capability of organization. TPM also helps to maintain consistency in quality of the product as well as reliability of product, the things that expect from the customer which interns helps to satisfy the customer.

The basic aims of TPM is to double productivity and eliminate the loses, to create bright, clean and pleasant factory, to empower people and facilities and,...

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