Why TPM is a More Comprehensive System Beyond Maintenance

 Definition and Scope of TPM

• TPM Explained: Defined TPM as a multifaceted approach encompassing maintenance methodology, manufacturing tool, and productivity management system, emphasizing its versatility and comprehensive nature.

• Key Components of TPM: Highlighted the multifunctional aspects of TPM as a maintenance method, manufacturing tool, and productivity management system within the broader context of operational excellence strategies.

Traditional TPM

• Traditional TPM focuses on achieving maximal equipment effectiveness through employee involvement, including management, operators, and maintenance staff.
• The Traditional TPM approach emphasizes a proactive approach to maintenance, shifting from reactive to preventive measures.
• Traditional TPM advocates for treating equipment as if it were one's own, fostering a sense of ownership and responsibility among operators and maintenance personnel.
  • There are parallels between caring for equipment and caring for personal belongings, such as a new car versus an older one.
• TPM sets a bold goal of achieving zero breakdowns and losses in equipment performance.
  • It emphasizes preventive maintenance strategies to proactively address potential issues and minimize downtime.
• TPM Pillars such as Quality Maintenance, Office TPM, and Safety are not as robust as other pillars, suggesting they were added later as a "bolt-on" necessity. 

Source:

 https://www.youtube.com/watch?v=vZY0ZL3izbE&list=PLyVgVZd7jUlrpaf8-9dvewh-snHTG6PN4&index=35

Importance of People and Processes in TPM

• Strategic Connection: Emphasized strategic alignment and the correlation of TPM with performance indicators, evaluation, and alignment with overarching strategic objectives.

• Process Management: Detailed the significance of process-oriented thinking, loss elimination, and cross-departmental integration as core components of TPM implementation.

• Cultural Transformation: Explored the transformative impact of TPM on organizational culture through leadership commitment, knowledge transfer, and ongoing employee development initiatives.

Examples of How Operational Excellence Evolves 

• Using Grupo Nutresa as an example...
  • In 1999, a plant in Colombia initiated a TPM "certification" path.
  • In 2001, it expanded expertise by acquiring Unilever's ice cream division at Mills, which marked the initial step towards operational excellence.
  • In 2006, it got acquired by Grupo Nutresa, which reinvigorated the focus on Total Productive Maintenance (TPM), emphasizing the commitment to implementing TPM methodologies across all acquired companies.
  • From 2006 to 2010, a comprehensive TPM implementation strategy extended to other plants in Bogotá and Manizales, demonstrating a strategic commitment to achieving operational excellence across locations.

Results and Transformations

• Operational Improvements: Showcased notable enhancements in safety protocols, compliance with programmed tasks, reduced delivery times, and successful integration into various logistics functions.

• Cultural Shift: Illustrated examples of employee growth within the organization, illustrating how cultural transformation influences individual career progression and overall organizational success.

• Impact on Safety: Specific details on safety protocol enhancements, including a reduction in accident rates and increased adherence to safety procedures due to TPM implementation and cultural changes.

Achievements and Continuous Improvement

• Delivery Performance: Discussed achievements in meeting plant programming requirements, customer satisfaction through improved delivery performance, and notable enhancements in service delivery.

• Process Enhancements: Highlighted tangible process improvements, problem-solving initiatives, and skill development leading to improved team performance and continued cultural evolution.

• Inspections and Compliance: Emphasized successful inspections and regulatory compliance owing to TPM implementation, particularly in areas such as personal protective equipment and safety protocols.

Evolution towards Excellence

• Role of People: Stressed the pivotal role of employees in driving organizational excellence, emphasizing their influence on significant progress and cultural shifts within the company.

• Organizational Transformation: Demonstrated the transformative journey of the organization towards operational excellence, detailing various initiatives and continuous improvement efforts undertaken to achieve this goal.

• Final Impact: Concluded with the assertion that operational excellence is attainable and reiterated the importance of the human element in accomplishing and sustaining this goal.

Course Forward:

• Consider sharing with others to understand why TPM is more comprehensive than just Maintenance, just at one Site, or just in Operations.
• And if you'd like to learn more about TPM or WCM (WCM is an evolution of TPM which attempts to modernize TPM and add other managerial pillars and technical pillars which were a gap in TPM), please visit our blog sections...
  • TPM:  https://www.beltcourse.com/blog?tag=total+productive+maintenance
  • WCM:  Note there will be a lot of overlapping articles, but that will help you also see the similarities and differences between TPM and WCM.   https://www.beltcourse.com/blog?tag=total+productive+maintenance

Source: 

• Best video on the reasons for a comprehensive TPM approach below.
• Yes, it's in Spanish, but you can translate and listen to your own language...
  • Learn how here:  https://www.beltcourse.com/blog/translate-and-listen-to-youtube-videos-in-any-language-dub-with-speak-subtitles-for-youtube) 

 https://www.youtube.com/watch?v=Pz2ZWjwhEGk