Page 29 - TPM A Route to World-Class Performance

10 TPM-A Route to World-Class Performance

from breakdown and towards predictive and preventive approaches. The
histogram chart in Figure 1.8 serves as an indication of objectives for
improvements in performance from the present unsatisfactory levels to
benchmark levels.
Japanese methods have been at the heart of the transformation in
manufacturing efficiency which has taken place over the last twenty to thirty
years and which is still going on. There are common threads running through
all of these methods:
0 Developing human resources
0 Cleanliness, order and discipline in the workplace
0 Striving for continuous improvement
Putting the customer first
0 Getting it right first time, every time
Central to all these approaches to manufacturing efficiency is the concept
of TPM. Asset care has to become an integral part of the total organization so
that everyone is aware of, and involved in, the maintenance function. The
end result is that breakdowns become a positive embarrassment and are not
allowed to occur. The assets of the production process are operated at optimum
efficiency because the signs of deterioration and impending failure are noticed
and acted upon.
Asset care covers three interrelated issues combining autonomous
maintenance and planned preventive maintenance.

0 Cleaning and inspection: Daily activities to prevent accelerated wear
0 Checks and monitoring: Early problem detection and diagnosis
0 Preventive maintenance Injection of relevant technical expertise to
and service: prevent failure and restore condition

I Current vs. benchmark maintenance practices I

I

%40% 20 0

Reactive Preventive Predictive Proactive
Current
Benchmark
Figure 1.8 Asset care balance