Page 112 - TPM A Route to World-Class Performance

The TPM improvement plan 93

Each heading will have been subdivided as necessary: for example, the
electrical section may contain power supply, control panels, motors and lighting.
Under each of the subdivisions of the equipment being studied, four
categories should be established:
Satisfactory
0 Brokendown
0 Needs attention now
0 Needs attention later
An example of the outcome of a condition appraisal study is shown in Figure
5.17.
The key point of the condition appraisal is to put each square centimetre
of the equipment under the microscope and assess whether its condition is
‘as new’ or ’as required’. Make sm also that you look inside the machine, so
remove all panels. This is not just a broad, superficial look - on the contrary,
it is being obsessive about attention to detail.
As such, the condition appraisal stage must include a deep clean of the
equipment.

Step 6 Refurbishment
The objective of the refurbishment programme is to set up a repair and
replacement plan, based on the condition appraisal, and indicating the resources
needed. Getting the equipment back to an acceptable level is a prerequisite to
the pursuit of ideal conditions.
The plan will provide a detailed summary of actions to be co-ordinated by
the team, which will include:
0 dates and timescales
0 resources (labour, materials, time)
0 cost estimates
responsibllities
0 control and feedback (management of change)

A typical summary table of refurbishment costs and man-hours required for
a group of critical machines is shown in Figure 5.18.
The chart in Figure 5.19 gives details of action required on a specific item
of equipment. It allocates responsibility for the various tasks and nominates
individuals to carry out the work; it also embodies a simple visual indication
of work progress.
The refurbishment programme is concerned not just with clearly idenaable
repair work, but also with the many small weaknesses identified by the
condition appraisal, including cleaning and CAN DO approach, such as missing
bolts, leaks, temporary repairs and over/under-lubrication, and it highlights
critical points for regular attention.