[TPM] [TOTAL PRODUCTIVE MAINTENANCE] – [1st]

-    Up to the previous edition, I have been explaining “Production Control based on my own personal ideas.  However, as of now I hope to introduce “total productive maintenance” with a different prospective by injecting in my own feeling as well.

 

-    In smt factory to get involved in management field is meant definitely to plan in details the proper  “maintenance” procedures.

-    The target of “facility maintenance” in Customer Satisfaction is based on “Quality, Cost and Delivery” which requires human touch. When serving customer, you need to offer them the faultless facilities which include serving customer with top quality service by cutting cost, offer high volume and cut down time wastage.

 

In short: (Well maintained facility should not face the following problems):

1.  The condition of the Machine should be defective free towards zero defect (there is no excuse for any defect to surface). This will ensure high productivity.

2.  Good conditioned Machine will never suffer from malfunction (thus, customer can expect perfect on time delivery).

3.  Well maintained Machine will not need any adjustment (factory will be having continuous production, and therefore there will not be any time and product wastage).

4.  Always practice safety first which is the basic safety fundamentals to ensure safe working environment.

-      There are 4 methods in “maintenance” procedure to follow in order to achieve the above targets:

a)    Breakdown Maintenance

-      after machine breakdown or exceeded defective limit

-      or facing dangerous working situation which hampers safety.

b)    Preventive Maintenance

-    daily inspection to ensure non breakdown, non defect.

-    Routine inspection, practice tolerance measure, regular over-haul and lubrication.

-    Worn out parts to be replaced.

c)  Corrective Maintenance

-    Modify facility to ensure less or no breakdown, less defect and easy maintenance.              

-    Also, target for easy make-over, easy maintenance and easy lubrication.  

d)  Maintenance Prevention

     -    Create new procedure which enable us to achieve high reliability, easy and simple maintenance, and fuss free operating system.

-      Of the above 4 methods, b), c) and d) are especially the most important methods when performing maintenance work.

 

-      The differences in PM (Productive Maintenance) and TPM (Total Productive Maintenance) are:

-      PM means maintenance divisions with 4 activities (highlighted above).

-      TPM is whole factories activities involving from top management to all operators.

-      The difference is not only in its scale, but also there is target to be achieved.

-      TPM provides good maintenance facilities, total efficiency and improvement in LCC (Life Cycle Cost), which is profitable PM.

-      (Total Facility efficiency = machine top running rate and performance rate x good products).

     -    In order to cope with the demand in “Sudden Market Changes and flexibility” one has to make haste to establish the Control System and TPM which will assist us to meet the demand in sales.

     -    Finally, the ability to meet the changes in customer’s demands would be our ultimate manufacturing Target.

 

 

 

 

(QUOTED BY MR BERDIE (28 APRIL 2011)