Total Productive Maintenance (TPM) arises from Japan as a system designed to eliminate equipment’s Six Big Losses related to their condition. Its purpose is to maximize availability according to the production schedule, generating products at the highest capacity, according to the expected quality, and without unscheduled stops.
To achieve improvements in production, maintenance, quality, and engineering at your factory, the Six Big Losses that need to be addressed are the following:
In each of the above cases, the machine is considered unproductive, affecting its efficiency and capacity, increasing costs of production, and reducing profits.
Failures of equipment and minor stops affect the machine’s availability. A machine with poor availability idles without generating profits.
Minor stops and reduced speed affect the execution, and use of the capacity of the machine. Equipment whose capacity is underutilized is unproductive and unable to comply with the production plan because it does not work at the speed for which the plan was designed.
Reduced yield, defects, and rework of the process affect the profitability of the business since the benefits obtained are affected when analyzing the total resources used.
The timely analysis of accurate and reliable data related to the Six Big Losses of production equipment determines the success of the actions implemented to counteract them. A significant challenge is the availability and reliability of the manufacturing data according to these criterions:
The visibility of the manufacturing data is crucial to proper handling of possible problems on the shop-floor.
Advanced technology to monitor the manufacturing process plays a fundamental role in guaranteeing this visibility. Identifying problems and their indicators helps to target the real losses and their root causes, which is essential to preventing a repetition of these costly events.
The data related to each of the Six Big Losses of your equipment can be easily obtained in detail with the M-Box production monitoring system. This will set you on the right track of improvement to further advance your OEE (Overall Equipment Effectiveness) through consistent concentration on solving the real problems with your equipment.