Adopt TPM for a sustainable future

15th May 2007

Over the last couple of months, I have become utterly convinced that the implementation of ‘Total Preventative Maintenance’ can have profound and significant results in the workplace. Not only can productivity be increased, thereby boosting bottom line profitability, but successful implementation can also bring environmental and sociological benefits.

TPM is an acknowledged tool within the Lean Toolbox and it sits comfortably with 5S, SMED and OEE. It can mean different things to different people – Total Productive Maintenance or Total Preventative Maintenance. The focus of my research, however, has been on Total Preventative Maintenance (TPM) and how through the effective and sustained adoption of this tool, the life span of machines and equipment can be extended, output increased, costly downtimes avoided and running costs reduced.

TPM can be adapted by degrees to take into account differing production schedules, staff levels and planned maintenance so, even if diluted, the process is still an effective way of improving productivity levels.

Companies that have adopted TPM successfully indicate the particular effectiveness of preventative maintenance. One leading manufacturer in Plymouth identified a problem when a machine was recorded as using more oil than usual. The problem was visible and rectified within days avoiding costly down times and potential loss of productivity.

Traditionally, TPM has been seen to engender a culture of empowerment, deliver extra skills to the workplace and provide reliability in projected capability but I believe that, in addition, TPM can contribute significantly to building a sustainable business and protecting the environment.

In removing the need for even just one new machine because the life of an original machine is extended, significant environmental benefits can be gained.

Just imagine, if by adoption of a preventative maintenance regime, just one company in each city across the world extended the life of one of their machines, obviating the need to manufacture from resources that are rapidly diminishing. The multiplier effect of this would have a real and significant environmental benefit, not only through reduction in materials mined but also in avoiding the energy required to make and transport these new machines. These global benefits are also complemented within a company by avoidance of unnecessary capital expenditure.

Poorly maintained and neglected machinery can incur extra energy usage and can spoil the manufactured product or create defects resulting in additional wastage. What’s more, if machines are not cared for within an organisation, this may impact the way the workforce feel about their own role or value, thus decreasing morale and productivity.

Complacency or disregard for TPM could mean the difference between a successful enterprise making the most of its opportunities in a sustainable, responsible and ethical manner against a possible scenario of recycling and disposal costs plus, the potential loss of jobs and opportunities.

If you would like to discuss how TPM could benefit your company with Linda or any other member of the South West MAS team, please do not hesitate to contact us.

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