Page 403 - Improving Machinery Reliability

Maintenance for Continued Reliability 367

The ability of operators to take fast corrective action is essential to improving
equipment effectiveness. New standards must be set to incorporate the additional
tasks, and targets established with supervisors for maximizing equipment uptime.

Team activities. The success of the TPM program depends on the formation of a
formal organizational structure consisting of operations and maintenance teams that
are superimposed on the existing structure. Groups must meet on a regular basis and
on company time. Success or failure of the teams is linked to the motivation, skills,
and training of team members. Likewise, management must create a working envi-
ronment that fosters positive change. This can be accomplished through involvement
in the program, providing physical surroundings conducive to work and meetings,
and monetary support for the TPM program and the ideas it generates.
Training of team members must be both technical and behavioral. Technical train-
ing consist of, but is not limited to:

* Fastener and joint theory
Bearing maintenance
Basics of gears, belts, chains, and pulleys
Sealing techniques
Basic tribology
Principles of electrical, pneumatic, and hydraulic systems

Safety is an essential component of all technical training.
Behavioral training includes motivation theory, group dynamics, brainstorming
techniques, problem solving, and management of change. Behavorial training will
ensure that technical training is exploited to its fullest.
To summarize, TPM concentrates on the elimination of waste. Waste exists as:
Downtime

1 Equipment breakdown
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2. Set-ups and changeovers
3. Lack of material or manpower

Inefficiencies

1. Inadequate tools or parts to effect repair
2. Equipment design flaw
3. Substandard material input
4. Equipment deterioration
5. Poorly trained workers
6. Blockages
7. Pollution
8. Sporadic usage