TPM Activity Charts- An Essential Feature of TPM
Activity Charts and how they are prepared and used?
Whichever plant you visit that is either implementing TPM or has implemented it, you will find one thing very common. The plant would be full of charts and display boards. The employees would proudly invite you to their plant and observe the Activity Charts, that they have prepared themselves. 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 use of TPM Activity Charts, which are used to track equipment performance and identify opportunities for improvement. TPM Activity Charts help organizations to monitor the effectiveness of their maintenance processes and identify areas for improvement.
TPM Activity Charts are prepared by:
- TPM Circles or Autonomous Maintenance groups also called Jishu Hozen Teams.
- Departmental Activity Charts, prepared by the Departments as a whole.
- Plantwide Activity Charts, prepared by different TPM Pillars and displayed at a central location, preferably at the Main Gate, of the plant. TPM Secretariat offers support for them and various Pillars present their activities to them.
TPM Activity Charts display two types of data:
- Plant Performance Charts: TPM Activity Charts are prepared by collecting data on equipment performance, including downtime, breakdowns, and changeovers. The data is then used to create a chart that shows the equipment’s overall performance over time. The chart is typically divided into three sections: Availability, Performance, and Quality.
- TPM Process Related Charts: These include abnormalities found, rectified, and in progress, Circle Meetings taken place and attended, Kaizens taken up and implemented by the TPM Circles, No. of OPLs generated and shared among the teams, Pillaar-wise performance records, benefits accrued due to TPM activity in units and plants, etc.
Plant Performance Charts:
The Availability section of the chart tracks the equipment’s uptime, or the percentage of time that the equipment is available for production. This section also tracks the equipment’s downtime or the amount of time that the equipment is not available for production. Downtime can be further categorized into planned and unplanned downtime. Planned downtime is the time that the equipment is intentionally taken offline for maintenance or other activities, while unplanned downtime is the time that the equipment is unexpectedly out of service due to breakdowns or other issues.
The Performance section of the chart tracks the equipment’s efficiency, or the percentage of time that the equipment is producing at its maximum rate. This section also tracks the equipment’s speed loss, or the amount of time that the equipment is operating at less than its maximum speed. Speed loss can be further categorized into minor and major speed loss. Minor speed loss is a temporary reduction in speed, while major speed loss is a sustained reduction in speed.
The Quality section of the chart tracks the equipment’s defect rate or the percentage of products that are produced with defects. This section also tracks the equipment’s setup time or the amount of time that it takes to change the equipment over from one product to another.
Improvement Action based on Charts:
Once the chart is prepared, it is used to identify opportunities for improvement. The chart helps organizations identify trends and patterns in equipment performance, which can be used to pinpoint the root causes of equipment failures and inefficiencies. For example, if the chart shows a high amount of unplanned downtime, the organization can investigate the causes of the downtime and take steps to prevent similar issues in the future.
TPM Activity Charts are typically used by cross-functional teams that include representatives from maintenance, production, and quality departments. The team leader is typically a TPM expert who is knowledgeable about TPM principles and practices. The team reviews the chart regularly to identify opportunities for improvement and to monitor the effectiveness of their maintenance processes.
The benefits of using TPM Activity Charts are numerous. First, TPM Activity Charts help organizations to monitor the effectiveness of their maintenance processes and identify areas for improvement. Second, TPM Activity Charts help organizations to reduce downtime, improve equipment reliability, and increase overall efficiency. Third, TPM Activity Charts promote a culture of continuous improvement by involving all employees in the maintenance process.
TPM Activity Charts are an essential element of TPM and a powerful tool for improving equipment performance and productivity. By tracking equipment performance and identifying opportunities for improvement, organizations can optimize their maintenance processes and reduce downtime, which can lead to significant improvements in overall efficiency and profitability.