Page 69 - TPM A Route to World-Class Performance

50 TPM-A Route to World-Class Performance

Condition appraisal
Following the above step, the TPM pilot teams can start the equipment condition
appraisal. Typically a team will comprise a team leader with two operators
and two maintainers as team members plus, of course, the TPM facilitator.
The TPM pilot team should start the condition appraisal by carrying out a
comprehensive clean-up of the equipment to see where deterioration is
occurring. This will include removing panels, so that a deep clean can be
carried out.

Refurbishment
The next task of the TPM team is to decide what refurbishment programme
is required in order to restore the equipment to an acceptable level of condition
from which the ideal condition can be pursued. Depending on the extent of
refurbishment needed, up to three work packages may be appropriate:
0 Work that can be done 'on the run'
0 Work requiring an 8- to 24-hour outage
0 Project work involving redesign and/or subcontractors
Future asset care
Whilst completing the condition appraisal the team can also determine the
future asset care programme in terms of who does what and when. They can
decide the daily prevention routines - the lubricate, clean, adjust and inspect
activities, which will be carried out by operations staff. They can also decide
upon the condition monitoring activities needed to measure deterioration -
remember that the best condition monitor is the operator using the machine.
The operator acts as the ears, eyes, nose, mouth and common sense of his
maintenance colleague and can call him in when things start to go wrong and
before they become catastrophic. Finally, the team also decides upon the
regular PPM - the planned, preventive maintenance - and contribute to the
condition monitoring, whilst the maintainer does the PPM scheduled work.
This asset care step also determines the spares policy for the specific equipment
under review.

Problem prevention cycle

Best practice routines (BPRs)
The TPM pilot team will develop its own BPRs regarding the equipment
operation and asset care policy and practice. All these feed back into an
improved OEE score which will encourage the continuous improvement 'habit'
- this is central to the TPM philosophy. As in total quality, the personnel will
also become empowered!
Problem prevention
This final step is about getting at root causes and progressively eliminating
them. P-M analysis is a problem-solving approach to improving equipment
effectiveness which states: There are phenomena which are physical, which