Understanding Total Productive Manufacturing (TPM)

Total Productive Manufacturing is a holistic approach to equipment use and maintenance that seeks to achieve perfect production. Its scope covers zero accidents, zero breakdowns, and zero defects. By adopting TPM principles, organisations can empower their workforce, streamline production and maintenance processes, and ensure that operations run reliably. The goal of TPM is to raise Overall Equipment Effectiveness (OEE), a key performance indicator that measures the uptime, efficiency and quality of the production process.

Lean Thinking: Eliminating Waste

Lean Thinking focuses on creating more value with fewer resources by eliminating waste. It is essential for organisations striving for operational excellence. Combining TPM with Lean Thinking ensures a systematic approach to workflow, productivity and customer value. This integration helps in identifying and addressing the causes of accelerated wear on equipment, thereby enhancing reliability and performance. Additionally, Lean Thinking principles incorporate standardisation and simplification of work routines which significantly improve maintenance added value.

The Role of Digitisation in Modern Manufacturing

Digitisation in manufacturing plays a crucial role in enhancing TPM and Lean Thinking efforts. The adoption of digital technologies such as the Internet of Things (IoT), predictive analytics, and machine learning can greatly improve the monitoring and maintenance of equipment. These technologies enable real-time data collection and analysis, providing insights into equipment performance and potential issues before they lead to breakdowns. By leveraging digitisation, organisations can achieve a state of Excellence that systematically improves predictive maintenance to minimise unscheduled downtime, and continuously improve OEE.

Achieving Zero Breakdowns

One of the goals of combining TPM, Lean Thinking, and Digitisation is achieving zero breakdowns as a launch pad to eliminate the causes of quality defects. This ambitious target can be met by creating a culture of continuous improvement and engaging the organisation with reducing waste and hidden losses. Employees at all levels work in teams to identify inefficiencies, suggest improvements, and implement solutions. Collaborative efforts and transparency in processes lead to a more resilient and efficient manufacturing environment.

Conclusion

Achieving Operational Excellence by blending best practices from Total Productive Manufacturing, Lean Thinking, and Digitisation raises OEE by reducing accelerated wear, and enhancing maintenance added value. With that in place organisations can steadily work towards the goal of zero breakdowns with less effort. That releases engineering time to focus on removing the causes of minor stops and reduced speed. The gains include improved quality, yield and Total Manufacturing Costs per unit. Continuous improvement, supported by digital advancements, paves the way for a more efficient, reliable, and engaging manufacturing environment.

Make TPM Lean and Digital

Cost: £4500 plus VAT for up to 10 participants

Learn how to accelerate TPM and Lean improvement gains in a connected Digital world.
This 3 day training workshop includes practical activities on the production shop floor to provide a "how to guide" to adopting Total Productive Manufacturing (TPM) and Lean Thinking principles using the enhanced connectivity of Digitisation and Smart Technology.

• For Organisations at the start of their digitisation journey:
  Learn how to apply the basics of TPM and Lean Thinking and use readily available digital platforms such as Microsoft Teams and SharePoint to accelerate the pace of improvement by linking up data from shop floor sensors and traditional IT systems.

• For Advanced organisations:
  Discover how to blend digital strategies with TPM and Lean Roadmaps to take your existing Digitised Manufacturing Processes to the next level.

3 Day In House Training Workshop