Total Productive Maintenance - Implementation | Autonomous Maintenance in Organization | Seven Steps Academy

Total Productive Maintenance - Implementation | Autonomous Maintenance in Organization | Seven Steps Academy






Many organisations start with great vigour in implementing TPM for greater benefits to the organisations. However, very few organisations succeed in realizing the full potential and within the reasonably accepted timelines. Some of the organisations implement all the pillars of TPM but will not sustain.
Common issues faced is while launching the TPM programme in most of the organisations, the benefits are always recorded and communicated one-sided. ie. What is it for the organisation when they implement.
Common benefits listed are:
  • Improved on-time performance
  • Improved quality
  • Improved productivity
  • Reduced breakdowns
  • Reduced investment
  • Improved business results and so on.
However, the critical part which is not addressed is about  What is in it for me  (WIIFM) if I support TPM… This is the question from the front line or the operator’s point of view. 
For Example:
Implementing Autonomous maintenance is very essential and a company gets multi-skilled operators who not only operate the machine but also maintain their own machine. However, by implementing Autonomous Maintenance, “what is in it for me for an operator” is not addressed by the organisation. Some organisations may have the inputs but it is not effectively communicated and the consensus is not there resulting in semi-partial involvement of front line.

Traditional companies who are not into the Total Productive maintenance program has the following characteristics,

  • Ownership is not given to operators in maintaining their machines in the true spirit
  • No investment is done on operators in improving their skill levels
  • High dependence on maintenance and engineering team even for small things
  • Unsafe workplaces due to trip/fall hazards
  • High work pressure due to frequent breakdowns of machines and production demands
  • Less support from other team members
  • No job satisfaction
  • Career advancement purely depends on the individual
  • Work-life balance is low

Key advantages of implementation of Autonomous maintenance in an organization are:

Autonomous maintenance helps in
  • Zero BAD (Breakdowns, Accidents and Defects)
  • Improves on-time performance
  • Helps in adhering to compliance effectively
  • Lower cost of maintenance due to reduced breakdowns and timely restoration of basic conditions.
  • Improved machine availability.

What is in it for me for operators are:

  • For future expansions and new plants, we need skilled leaders who are grown within. Skilled leaders, who have intensive knowledge about processes and products, are preferred.  Hence, the first priority is to grow the people to leadership roles from within the organisation. Having the knowledge of machine and its functions helps the front line members to move faster in the direction of career advancement.
  • Being an Equipment conscious member will make operators daily work easy. Having knowledge of machine and its parts through “Know your machine” Helps in identifying the areas where safety is to be followed. Key elements that help in quality and productivity will be known. This will also ll helps in getting things first-time-right with the right efficiency.
    This reduces daily fire- fighting and helps in completion of day to day work on time.  It also helps in work-life balance
  • Multiskilling helps: Ontime completion of daily jobs releases quality time for learning new things.  This increases self-confidence and also the ability to look at things in a holistic view.
  • Self-development: Continuous learning and ability to do systematic problem solving give a sense of satisfaction and pride in work. This, in turn, boosts the morale and gives a chance to apply the best practices in personal life too. Both tangible and intangible benefits can be observed from this self-development
  • Ability to train others: Training of newcomers will be more efficient and less time consuming due to vast knowledge gained in day to day operations. Developing newcomers gives great satisfaction and fulfilling experience.
  • Increases Job security Retention rate of key team members with multi-skilling and effective management of machines is higher compared to those who perform any one role only. High importance and respect will be naturally available for those who are key members of the organisation.
The following  Trainings related to Total Productive maintenance helps organisations ineffective implementation of the programme:
  1. Autonomous maintenance training for front line members
  2. Autonomous Maintenance for Quality team members.
  3. Autonomous maintenance for Engineering team members.
  4. Autonomous maintenance for office staff.
  5. Focussed equipment improvement for the TPM team members.
  6. Maintenance planning and management for Engineering and technical team members.
  7. Planned maintenance for management team members.
  8. Implementing Know your Equipment
  9. Critical Spares management for TPM implementation.
  10. Predictive maintenance and condition-based maintenance for TPM implementation.
  11. Reliability Engineering for TPM implementation.
  12. 5s training for operators and managers
  13. Kaizen training for front line
Seven Steps Academy of Excellence offers customized organisation specific training programme in Total Productive Maintenance.  These programmes are offered both as an in-house programme or public programmes.
Apart from training on Total productive maintenance, we also offer
  • Lean Six Sigma Green belt training
  • Lean Six Sigma Black Belt training
  • Lean Six Sigma Yellow Belt training
  • 5s auditor training programme
  • Lean professional training
  • Certified precision Manufacturing engineer
  • Lean logistics and supply chain
  • 5s for banking
  • 5s for hospitals
  • 5s and Lean in construction management
  • Lean layout training
  • Kanban and supermarket training
Seven Steps Academy of Excellence provides training services in the field of Lean manufacturing, Lean Services, Lean Hospitality, Lean hospitals, Lean Supply Chain, Lean warehousing, Lean retain.  As part of this, tools and methodologies for training includes Applied 5S, Lean Experiential Learning programmes, TPM Training, Six Sigma Green Belt and black belt training, Lean Six Sigma Yellow belt, green belt and black belt, Kanban supermarket. Apart from this, Campus to corporate programmes in precision engineering is also offered to aspiring engineering and diploma graduates through the focussed skill development programme.
Through their group company – Seven Steps Business Transformation Systems, we also offer consulting services.  We have consultants specialised in various methodologies and has worked as Lean consultants, Lean Six Sigma Consultants, TPM Consultants, 5S consultants, Lean layout consultants.  We operate all over India and having branches in Bangalore, Chennai, Mysore, Hosur, Pune and have a customer base in Delhi, Calcutta, Gurugram, Neemrana, Pant Nagar, Nashik, Pune, Hyderabad, Vishakapatnam, Vijayanagaram
Some of the flagship training programmes conducted at Seven Steps Academy of Excellence are:
Six Sigma Yellow Belt
Skill development programme – Campus to Corporate – Precision Engineering
Lean Experimental Learning Programme

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