Page 30 - TPM A Route to World-Class Performance

TPM-from total productive maintenance to total productive manufacturing 11

These are described in more detail in Chapter 3. It should be recognized
that asset care is something that evolves with experience. Once established,
it is refined to reflect the improved equipment condition.
Firsf sporadic losses
The route to high levels of reliability is reasonably predictable. Asset care is
directed first towards sporadic losses. These are sudden failures such as
breakdowns. They can be almost totally removed by improving equipment
condition, reducing human error through training, fool-proofing and
establishing how to detect potential failures before they occur. Experience
shows that effective asset care can detect 80 per cent of potential component
failures and stabilize the life span of the remaining 20 per cent. This is why
zero breakdowns are becoming an accepted reality in most world-class
operations.

Then optimiza fion
Once sporadic losses are under control, the target becomes chronic losses.
These require improved problem-finding skills. As such, asset care is refined
to look for minor quality defects which direct first the definition and then the
implementation of optimum conditions.
The seven steps of autonomous maintenance provide the route map to this
evolution but, to be effective, must be supported by similar restructuring of
planned maintenance activities.
These two activities are the core of the improvement zone implementation
process described in Chapter 8. Teams translate management standards into
local policy/ best practice covering the following:
0 Basic systems of problem detection, including initial cleaning and
information, to understand the root causes and develop countermeasures;
Basic lessons of maintaining equipment condition and increased
understanding of equipment functions to correct design weaknesses
and systemize asset care;
Standardize and practise to achieve zero breakdowns and then optimum
conditions.

The senior managemenf role in asset care
The pace of progress through these stages is directly related to the priority
which management assigns to it. To simplify this effect, TPM identifies clear
management roles. These roles, known as pi2lar champions, provide leadership
in terms of:
setting priorities (where to start, what next?)
setting expectations (work standards to be applied consistently)
giving recognition (reinforce values)
The pillar champion roles and their relationship with the rest of the TPM
infrastructure is set out in Figure 1.9.