What Is Total Productive Maintenance?

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Total productive maintenance is a system (as a function of CMMS software) that can allow a company to reduce the amount of repairs that machines require, augment the capacity of numerous devices, carefully monitor the condition of equipment and perform routine maintenance autonomously.

The comprehensive strategy is able to augment the uptime of each machine and to increase the number of items that a facility produces.

Managing Equipment

When the program is first introduced, technicians should remove dust and oil from the machines, search for bolts and fasteners that have become worn, parts that may be leaking and corroded components. Additionally, the individuals should create detailed notes that describe any potential malfunctions and factors that could cause leaks or corrosion.

Organizing Inventory and Tools

The strategy will prompt individuals to place items in designated spots, and by utilizing TPM solutions, a technician can determine the location of each tool, the number of similar devices that are available and the condition of a tool. Moreover, the system lets users create a list of available components that are compatible with certain machines.

Providing Comprehensive Training

When using the system, a company can help representatives to create detailed reports that describe a machine’s issues or numerous types of routine maintenance that have been completed. Technicians will also be able to perform group activities that allow experts to analyze changes that can improve performance and reduce overall downtime. Each individual will also learn to service numerous types of machines and to install a wide variety of parts.

Some businesses may create detailed guides that evaluate procedures, lessons and strategies for repairing certain parts. In addition to printing the guides, experts may use total productive maintenance software in order to create visual models of components, machines and techniques that the lessons describe.

Evaluating Equipment’s Status and Overall Performance

The system will help a business owner to determine the condition of each vital component and the date on which a part will require maintenance. In some cases, a user can install software that will evaluate the temperature of moving components, and if the temperature exceeds a set limit, the program can automatically send alerts to various technicians.

Boosting Output and Results

When using TPM software, a business can calculate the number of items that each machine produces every day, the percentage of products that are defective and the number of items that are returned. Furthermore, the software may help experts to evaluate the machine’s total profitability and downtime.

The Costs of Maintenance

According to several reports, approximately 45 percent of businesses primarily perform maintenance when a machine ceases to function properly. This strategy can decrease the lifespan of the device, damage other components and boost the cost of maintenance.

The system can allow a business to calculate the cumulative costs of spare parts that have been installed, necessary lubricants, diagnostic equipment, vital tools and expenses that are associated with services that contractors provide. Some programs may evaluate the quantity of pollutants that a machine is generating and the costs of reducing potentially toxic byproducts.

Evaluating Prospective Results

Numerous analyses have shown that TPM software may decrease the overall costs of manufacturing by more than 30 percent. The system can augment the number of products that machines create by 50 percent to 120 percent, yet the software is able to substantially decrease the number of accidents that occur in facilities of all types.

Businesses that use the software can notably reduce the percentage of customers who file complaints or post negative reviews. Furthermore, the system has allowed some companies to lessen the percentage of items that are returned by approximately 20 percent.

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