TPM – Total productive support (Total Productive maintenance)

ТPM – Total productive maintenance is a system, created and developed in Japan over several decades. With an initial focus on manufacturing and machinery, it evolved into a program, covering almost all activities in the organization.

TRM is aimed at:

• creating a company culture that maximizes the efficiency of the production system;
• practical organization of production to prevent losses before they occur, throughout the life cycle of the production system with a view to achieving zero accidents, zero breakdowns and zero injuries,
• comprehensive involvement of all departments of the company, including. production, support, research and developed, marketing, etc.;
• engaging all employees from senior management to machine operators
• achieving zero waste through activities in "overlapping small teams".

We present TRM as one house with eight pillars, which are the main activities with their methodology.

Standalone support represents the duties of the operator in maintaining the so-called. "main condition of the machine" - cleaning, lubrication, inspect and tighten. They prevent accelerated depreciation of equipment, the anomalies on the machines are corrected, downtimes due to minor breakdowns are eliminated, defects and other losses.

"Scheduled Maintenance" engages support staff in activities, aiming increasing the effective pool of working time on the machines. Freed from the small daily problems, they focus on the preventive maintenance system and spare parts management, as well as in realization of Kaizen (machine improvements).

"Focused Improvement" directs all activities in TRM regarding detection and elimination /or at least reduction/ of losses in the production system. The losses according to TRM are: downtime and work interruption; reduced performance, product defects, surplus materials and PPE, excess transportation and handling, energy and material losses.

"Education and Training" aims continuous staff development and especially the workers,by assessing skills and providing adequate training.

„Quality maintenance” is aimed at determining, standardizing and fixing conditions for machinery, methods and materials in order to achieve products without quality problems.

"Control of everything new" includes analyzing and documenting improvements made and problems fixed in equipment and processes, so that this information can be used when creating and deploying the new machines, processes or products.

"Safety, healthand environment" creates a system for a safe and healthy working environment, to achieve zero accidents.

"Office TPM”aims to make the administrative functions highly efficient, and provide timely assistance and services to production units.

5S is the basis of TRM. This system keeps the work environment well organized, orderly and clean as a condition for efficient work and smooth running of all activities.

Stimulating environment for the successful implementation of TRM, represents the building of mixed teams at all levels, to engage the potential of all staff.