Implementing Lean Manufacturing Six Sigma with TPM

Total Productive Maintenance, or TPM, is the foundation of several manufacturing philosophies, including lean manufacturing, JIT (Just In Time), and zero defects. While equipment maintenance has historically been considered revenue-losing activity, TPM considers it an integral component of waste reduction and quality. For this reason, TPM plays a significant role in implementing a lean manufacturing Six Sigma transformation.

Understanding TPM

Total Productive Maintenance sees the act of equipment management differently from traditional manufacturing beliefs. Under a TPM system, equipment maintenance is not considered a cost-generating activity. Instead, it is viewed as a necessary part of the overall manufacturing process. TPM acknowledges that equipment performance is subject to degradation, which in turn leads to production and quality degradation. Regular maintenance activities, then, are viewed as a pro-active measure to ensure quality, and actually contain costs.

Downtime as a result of equipment failure can be time-consuming and costly. TPM seeks to avoid lengthy downtime due to emergency repairs by controlling the cause of equipment failure as much as possible. By actively maintaining each piece of equipment and replacing parts on a timely basis, manufacturers improve performance and enjoy the benefits of a full equipment life cycle.

    TPM focuses upon identifying and addressing common sources of manufacturing waste, crucial to the success of a lean manufacturing Six Sigma transformation. These equipment bottlenecks can be as a result of the following issues:
  • Equipment breakdown
  • Operation speed
  • Setup Error
  • Mechanical defects
  • Start-up problems
  • Minor stoppages

TPM and Other Manufacturing Practices

A significant difference between TPM and other manufacturing concepts is its emphasis on cooperation between production and maintenance staff. Operators do not just run the machine, and maintenance works do not just fix equipment. Rather, both groups assume responsibility for regular equipment upkeep and repair.

As a result, TPM practices can increase an employee's feelings of ownership over their work area and performance. With workers sharing a sense of investment in the manufacturing process, production and quality benefit. These are also critical aspects of lean manufacturing Six Sigma.

Implementing Total Productive Maintenance

TPM implementation methodologies may vary between manufacturers. There are fundamental areas, however, that are typically covered including:

  1. Restore and repair equipment - Rather than wait for equipment failure, components are repaired or replaced on a routine basis, as needed.
  2. Eliminate contamination sources - Sources of substances in the environment that contribute to degraded equipment performance are identified and removed.
  3. Improve accessibility of equipment - Provide full access to all areas of the machinery to yield improved pro-active monitoring and maintenance efforts.
  4. Establish maintenance standards - Develop clear goals and scheduling to identify optimum conditions for equipment performance.
  5. Develop general maintenance skills in workforce - Adequate maintenance training enables all levels of the manufacturing workforce to participate in the program.
  6. Promote autonomous inspection by all levels of workforce - Encourage workforce involvement in TPM above and beyond scheduled and assigned duties.
  7. Organize work area - Removing clutter from the work area decreases the risk for equipment damage and worker injury.