Organizing TPM walk on a shopfloor
What is a TPM walk and what’s its purpose?
Total Productive Maintenance (TPM) is a comprehensive approach to equipment maintenance that involves all employees in an organization. One of the key elements of TPM is the TPM walk, which is a structured walk through the shop floor to identify opportunities for improvement and discuss maintenance issues with operators.
The purpose of a TPM walk is to improve the overall efficiency of equipment by reducing downtime, improving equipment reliability, and optimizing maintenance processes. A TPM walk involves observing equipment in operation, checking for signs of wear and tear, damage, or malfunction, and looking for opportunities to improve efficiency. TPM walks are conducted by a cross-functional team that includes representatives from the maintenance, production, and quality departments. The team leader is typically a TPM expert who is knowledgeable about TPM principles and practices. The leader can also be a senior executive, an external consultant, or the officer of the TPM Secretariate.
Benefits of TPM Walk
The benefits of conducting TPM walks are numerous. First, TPM walks help organizations identify opportunities for improvement and optimize equipment maintenance processes. Second, TPM walks promote a culture of continuous improvement by involving all employees in the equipment operation and maintenance process. Third, TPM walks help organizations reduce downtime, improve equipment reliability, and increase overall efficiency.
HOW TO CONDUCT A TPM WALK?
Organizing a TPM walk on a shop floor requires careful planning and execution. The following steps can help ensure a successful TPM walk:
Step 1: Define the Objectives of the TPM Walk
Before scheduling a TPM walk, it is essential to define the objectives. The objectives should be aligned with the organization’s overall goals and focus on specific areas that require improvement. For example, if the goal is to reduce downtime, the TPM walk should focus on identifying the root causes of downtime and opportunities for improvement.
Step 2: Identify the Participants
The next step is to identify the participants. The TPM walk should include a cross-functional team that includes representatives from the maintenance, production, and quality departments. The team should also include operators who are familiar with the equipment being reviewed.
Step 3: Schedule the Walk
The TPM walk should be scheduled during a time when the equipment is in operation. It is essential to avoid interrupting the production process, so the walk should be conducted during non-peak hours. The walk should be planned to cover the entire shop floor, and it should be conducted in a logical sequence.
Step 4: Prepare for the Walk
Before the walk, the team leader should prepare a checklist of items to be reviewed, such as equipment condition, cleaning, and lubrication. The team leader should also review the equipment history, including maintenance records, downtime reports, and operator feedback. The team leader should then brief the team members on the objectives of the walk and provide them with a copy of the checklist.
Step 5: Conduct the Walk
During the walk, the team members should observe the equipment in operation and check for signs of wear and tear, damage, or malfunction. They should also look for opportunities to improve the equipment’s efficiency, such as reducing changeover time, optimizing maintenance processes, and improving operator training. The team members should discuss their observations and document any issues or opportunities for improvement.
Step 6: Analyze the Results
After the walk, the team leader should analyze the results and identify the root causes of any issues or opportunities for improvement. The team leader should prioritize the issues based on their impact on equipment efficiency, and develop an action plan to address them. The action plan should include clear objectives, timelines, responsibilities, and resources required for implementation.
Step 7: Implement the Action Plan
The action plan should be implemented promptly, with the team leader overseeing the process. The team leader should track the progress of the action plan and provide regular updates to the management team. The team leader should also seek feedback from the operators and adjust the action plan if necessary.
Step 8: Monitor and Review
Once the action plan is implemented, it is essential to monitor and review its effectiveness. The team leader should track the results and report them to the management team. The team leader should also conduct regular TPM walks to identify any new issues or opportunities for improvement.
Summing it up, organizing a TPM walk in a shop floor requires a structured approach that involves careful planning and execution. The TPM walk is a collaborative effort that involves all employees in the organization and aims to improve equipment efficiency, reduce downtime, and optimize maintenance processes. By following the steps outlined above, organizations can conduct effective TPM walks and achieve their objectives.