Total Productive Maintenance Business Report 2020

Total Productive Maintenance Business Report 

Introduction

This business report is based on the implementation and determination of the Total Productive Maintenance (TPM) to operate and maintain different operational activities of machines.

In addition, Total Productive Maintenance (TPM) is basically a method to operate functions of machines for controlling waste during the manufacture process.The machine process is highly influential in the automotive industry for manufacturing vehicles.

This business report will critically examine the contribution along with limitations of the Total Productive Maintenance (TPM) in the vehicle manufacturing process in automotive industry.

Therefore, Total Productive Maintenance (TPM) is widely implemented in order to control the wastes during the process of production(Takahashi and Osada, 2014).

1 Role of Maintenance Engineering and Asset Management

In the field of automotive industry, the selection of efficient equipment plays an essential part that can be measured by the Total Productive Maintenance (TPM).

The role of maintenance engineering has also a critical evaluation that is influenced by Total Productive Maintenance (TPM). Talking about the facts, the maintenance engineering is not a span rather an asset which plays more critical role in the automotive industry.

In order to improve the manufacturing process, the part of maintenance hold an essential contribution in the automotive industry(Rich, 2014). In this way, the aim of the maintenance engineering is to enhance the manufacturing process of the vehicle industry.

Along with that, famous automotive companies strive to adopt the maintenance strategies in order to accomplish desired goals and objectives. In this way, the maintenance strategies mainly conclude the contribution of Total Productive Maintenance (TPM) in a wide field of automotive industry.

In other words, TPM is a kind of maintenance tool that used in the manufacture process for improved wastes. The application of maintenance engineering incudes involvement of operator, senior management for improved equipment process.

The application of Total Productive Maintenance (TPM) is used in different management systems of an automotive company such as site management, finance and accounts, construction engineering, project engineering, and operational facilities.

On the other hand, the assets management of the automotive industry also involves the contribution of the Total Productive Maintenance (TPM) for improved maintenance.

The implementation of the Total Productive Maintenance (TPM) also enhance the relationship between productivity and maintenance to demonstrate good care of organizational assets such as building and machines(Agustiady and Cudney, 2015).

In this way, the asset management of the automotive industry can be influenced and developed by the implementation of the Total Productive Maintenance (TPM) during the manufacture process.

In other words, the employees can realise the ownership feeling during the production process with the help of Total Productive Maintenance (TPM) and its applications.

A clear sense of the maintenance process is also being evaluated by the applications of the Total Productive Maintenance (TPM) to improve the asset management system(Borris, 2014).

Although, the senior management provides additional consideration to the employee’s job satisfaction for analysing the limitation of the Total Productive Maintenance (TPM) during the manufacturing process in automotive industry.

The production goals can be achieved by the implementation of Total Productive Maintenance (TPM) for collecting valid information regarding asset management. The quality of the products is also being measured by the applications of Total Productive Maintenance (TPM) that assists the management for employee encouragement.

The process of asset management is basically influenced by the Total Productive Maintenance (TPM) including a wide range of applications for enhancing the manufacturing the vehicles for reducing the wastes with the help of Total Productive Maintenance (TPM).

Conclusively, both maintenance engineering and asset management can be measured by the implication of Total Productive Maintenance (TPM).

2 Impact of Maintenance strategies

In order to increase the productivity of an organization, the management needs to focus on the maintenance strategy. In this way, the maintenance strategies also help the automotive industry to eliminate various risk factors.

The implementation of the Total Productive Maintenance (TPM) includes both applications and limitations to influence the maintenance strategies. In other words, the maintenance strategies also influence the mode of manufacture process through its applications in the sector of automotive industry(Davis, 2011).

Famous automotive company Toyota determined the contribution of the Total Productive Maintenance (TPM) for developing improved maintenance strategies during the manufacture process. In this way, both applications and limitations of Total Productive Maintenance (TPM) inspired the management of Toyota to develop and implement effective maintenance strategies.

Maintenance strategies

AdvantagesDisadvantages
Maintenance strategies increase manufacturing processMaintenance strategies highly influence organizational economy.
Maintenance strategies help management to reuse wastes.Maintenance strategies requires total monitoring process.
Maintenance strategies reduce time for customer satisfaction.Maintenance strategies requires technical leadership quality and expensive resources for development.

2.1 Applications

Major applications of the Total Productive Maintenance (TPM) was firstly introduced by the Japan base automotive company Toyota. The management of Toyota got help from the applications of the Total Productive Maintenance (TPM) on its production system.

In this way, the production system of Toyota was increased due to the implications of Total Productive Maintenance (TPM). Maintenance instability problem causes prevention in the production process that can be resolved by the applications of Total Productive Maintenance (TPM).

Along with that, the management of Toyota encouraged its employees about the urgency in the manufacturing process with the help of Total Productive Maintenance (TPM)(Maggard, 2012).

Major applications of Total Productive Maintenance (TPM) influenced the inventory system of Toyota to measure the cash statements for implementing effective maintenance strategies.In other words, the management of Toyota could analyse the mode of transactions by the applications of Total Productive Maintenance (TPM)(McTighe, 2012).

On the other hand, the scenario of lean production was also managed by the applications of Total Productive Maintenance (TPM).

In other words, the operator can stop production for maintenance issue that comes with crisis and a sense of urgency. With the support of Total Productive Maintenance (TPM), Toyota successfully tackled the maintenance planning during the high production process.

Along with that, Total Productive Maintenance (TPM) could systematically remove all risk elements during the lean production situation to avoid uncertainty and financial crisis.

Moreover, a stability was provided by the applications of Total Productive Maintenance (TPM) during the lean production of Toyota(Swink, 2015).

Apart from this part, maintenance strategies also involve the role of suppliers. In addition, the supply chain management is also being redesigned with the assistance of Total Productive Maintenance (TPM) in Toyota.

Basically, the supply chain management of Toyota was managed by the applications of Total Productive Maintenance (TPM). In order to manufacture high quality products, the management of any industry needs to ensure supreme quality of raw materials that provided by the suppliers(Varughese, 2013).

Growing demand of comfortable vehicles also allows the applications of Total Productive Maintenance (TPM) to engage more maintenance strategies to control the demands of the suppliers.

In other words, Total Productive Maintenance (TPM) includes some exclusive maintenance strategies, for example, negotiation plans, low operating rate, and increased profit rate.

In addition, Failure modes and effects analysis (FMEA) is a significant application tool of TPM that includes step-by-step approach for deducting different potential failures within a manufacturing process. In addition, FMEA can assist the management of automotive industry by suggesting modes or ways in which something might fail.

The management can develop more improved maintenance strategies with the support of TPM program and its FMEA application implementation process.

Conclusively, the applications of Total Productive Maintenance (TPM) helped the management of Toyota to implement effective maintenance strategies for increasing profit and productivity.

Although, with the help of Total Productive Maintenance (TPM), Toyota able to manage couple of issues such as a sense of urgency during lean production, lower operating costs, negotiation with suppliers and high quality production process.

2.2 Limitations

Along with the applications, Total Productive Maintenance (TPM) also includes some limitations that can be considered as losses such as breakdown losses, equipment adjustment losses, interruption losses, speed losses and slow running losses, defective quality and start-up/restart losses.

According to Szulc, (2015), the implementation process of Total Productive Maintenance (TPM) involves six major losses that can reduce the performance of any automotive organization, for example Toyota.

First of all, the breakdown maintenance are being influenced by failures operations in Total Productive Maintenance (TPM), for example, function-stopping failures and function-reduction failures while the equipment falls below normality in production process.

In this regards, the implementation process of Total Productive Maintenance (TPM) also includes set up and equipment adjustment losses that limit its utilization in the manufacture process(Agustiady and Cudney, 2018).

The lack of equipment adjustment also enhance the breakdown maintenancefor the utilisation of Total Productive Maintenance (TPM).The management of automotive industry can resolve the equipment adjustment losses by providing adequate training to the employees and engineers.

Along with that, one of the critical limitation of Total Productive Maintenance (TPM) is minor stoppages and interruption losses during the lean production of the automotive industry.

In this way, this limitation of Total Productive Maintenance (TPM) involves losses in the case of temporary stopped equipment that influences jamming in production and sensor actuation(Mcadam and Duffner, 2012).

The management of the automotive industry could not use simple measurements like removal of the job and resetting the equipment adjustments.

Another limitation of Total Productive Maintenance (TPM) is speed losses that cover all losses caused by real speed of operations to reduce the estimated speed during the manufacture process.

Be that as it may, the negative aspects of Total Productive Maintenance (TPM) includes some losses but the efficiency of work can be increased by resoling all issues and losses.

Talking about another significant limitation of Total Productive Maintenance (TPM) that includes defective quality and reengage the employees for re-production process. In this manner, the supplier’s contribution plays a critical role in this limitation of Total Productive Maintenance (TPM) of the vehicle industry(Mcadam and Duffner, 2012).

Last but not least, start-up losses are very important limitation of Total Productive Maintenance (TPM) that covers all material losses.

In order to produce high quality products, Total Productive Maintenance (TPM) cannot determine module of raw materials during the manufacture process.

Similarly, the management has to face many financial crisis due to the limitations of Total Productive Maintenance (TPM) in the manufacture process. Although, these limitations of Total Productive Maintenance (TPM) can be managed by inspiring training process and true leadership quality of the automotive industry.

Conclusively, the management of automotive industry needs to focus on the maintenance strategies comparison to measure the applications and limitations of Total Productive Maintenance (TPM)(Ireland and Dale, 2015).

Conclusively, these are big six losses of TPM. On the other hand, complete deployment process of Total Productive Maintenance (TPM) also involves certain expenses that might reduce the economic strength of an organization.

In other words, the applications of Total Productive Maintenance (TPM) are quite expensive that cannot be afforded by many organizations.

The accounts department needs to analyse the financial stability of its organization to deploy the Total Productive Maintenance (TPM) without any financial crisis.

High costs of equipment for TPM implementation is a critical limitation. Another limitation is high voltage power supply is another financial limitation of TPM. Highly technical observation is required for TPM that also considered as a limitation.

 

3 TPM Fundamentals

The implementation process of Total Productive Maintenance (TPM) includes three major fundamentals such as availability, performance and quality. A detail analysis about the fundamentals of Total Productive Maintenance (TPM) is conducted below:

Total Productive Maintenance (TPM)= Availability × Performance Efficiency × Rate of Quality product

Despite the fact that, the availability is also notified as uptime that gives a percentage of scheduled time, by which different operations can be managed during the manufacture process.

In this way, an original measurement of Uptime can be calculated by the Availability Metric in order to improve product quality, performance and scheduled downtime events in the manufacturing process(Takahashi and Osada, 2014). In order to calculate downtime availability, the management uses a formula is that,Availability = Available Time/ Scheduled Time

With the help of availability measurement, the management can determine estimated time for machine’s availability, for example, Availability = (Planned production time – Unscheduled downtime)/ Planned production time

Similarly, Production time = Planned production time – Downtime

On the other hand, another critical fundamental of Total Productive Maintenance (TPM) is performance efficiency that reflects the design capacity vs. real.

In this way, the management can measure the performance of their employees through monthly sales growth that isa key performance indicator.

The sales growthof an organization can indicate thesales speedof an employee with the support of Performance Metric and Key Performance Indicator (KPI).Talking about the calculations that defines Performance = (Parts Produced × Ideal Cycle Time)/Available Time.

In this way, the management of the automotive industry can also examine speed efficiency and rate efficiency through reviewing this performance efficiency fundamental of Total Productive Maintenance (TPM).

The rate efficiency includes some critical calculations for measure jams in progress, minor recorded stoppages, and adjustment losses to increase the productivity. The formula of performance efficiency can be conclude in this way Performance (Speed) = (Cycle time × Number of products processed)/Production Time

Aside from that, rate of quality is another critical fundamental that refers to detect faults during the production process.

The Quality Rate Metric is considered as genuine measurement of process yield to eliminate the impression of performance and availability. In this way, the rate of quality also reflects the percentage of good parts out of entire amount of produced parts during the manufacture process.

The formula of Quality Rate is followed below:

Quality (Yield) = (Number of products processed – Number of products rejected) × (Number of product processed)

Moreover, the fundamental of Total Productive Maintenance (TPM) mainly influence the performance efficiency, availability and rate of quality products of the automotive industry to increase the probability and productivity.

Conclusively, Total Productive Maintenance (TPM) involves some drawbacks but the applications can surely increase the manufacturing process of the automotive companies.

4 Major activities to deploy TPM

In order to successfully deploy the Total Productive Maintenance (TPM) within an organization, the leaders need to investigate a couple of things. In other words, the leaders of an organization have to initiate some activities to deploy the Total Productive Maintenance (TPM) within the workplace.

The leaders should consider the cost accounting process for deploying Total Productive Maintenance (TPM) which is an expensive tool.

Along with that, the capability of machines should be examined before the deployment of Total Productive Maintenance (TPM) at workplace(Agustiady and Cudney, 2015).

Preventive maintenance is another critical element that should be considered by the organizational leaders for successful deployment of Total Productive Maintenance (TPM).

In this way, the leaders need to supervise the mode of preventive maintenancefor effective deployment of the Total Productive Maintenance (TPM) within the workplace.

Lastly, the leaders of an organization should arrange a training program for increasing the learning experience of the employees for improved deployment of Total Productive Maintenance (TPM).

It is highly recommended that, the leaders of an organization   only can increase the adaptability power of its employees by providing adequate training facilities.

In contrast, the deployment of Total Productive Maintenance (TPM) could not successful without training sessions. The employees can also increase the personal skills like technological knowledge, communication level and intelligence.

The management of an organization needs to take these actions for successful implementation of Total Productive Maintenance (TPM) within the workplace.

In this regards, Total Productive Maintenance (TPM) can be influenced by the condition monitoring process for improving the employee performance.

The condition monitoring processcertainly increase the adaptability power of the employees that could help to manage employment relations within an association.

Conclusively, successful deployment of Total Productive Maintenance (TPM) can enhance the condition monitoring processof an organization to achieve selected goals and objectives(McTighe, 2012).

Conclusion

This business report justified the role and contribution of Total Productive Maintenance (TPM) during the manufacture process of the automotive industry.

Similarly, the automotive industry was selected due to involvement of advanced equipment and machines for analysing the applications and limitations of Total Productive Maintenance (TPM).

In this manner, role of maintenance engineering and asset management both were analysed in this report to justify the effect of Total Productive Maintenance (TPM) in manufacture process.

Both applications and limitations of Total Productive Maintenance (TPM) were also defined in this report along with proper argument and justification.

References

Agustiady, T. and Cudney, E. (2015). Total productive maintenance. USA: SEGA Publication.

Agustiady, T. and Cudney, E. (2018). Total productive maintenance. Total Quality Management & Business Excellence, pp.1-8.

Borris, S. (2014). Total productive maintenance. New York: McGraw-Hill.

Davis, R. (2011). Productivity improvements through TPM. New york: Prentice Hall.

Ireland, F. and Dale, B. (2015). A study of total productive maintenance implementation. Journal of Quality in Maintenance Engineering, 7(3), pp.183-192.

Maggard, B. (2012). TPM that works. Pittsburgh: TPM Press.

Mcadam, R. and Duffner, A. (2012). Implementation of total productive maintenance in support of an established total quality programme. Total Quality Management, 7(6), pp.613-630.

McTighe, E. (2012). Total productive maintenance. Cambridge, Mass.: Productivity Press.

Rich, N. (2014). Total productive maintenance. Great Britain: Liverpool Business Pub.

Swink, M. (2015). Managing operations across the supply chain. New York: McGraw-Hill Irwin.

Szulc, T. (2015). Analysis of possibilities of implementation of Total Productive Maintenance (TPM) concept in public services organisations. Mechanik, (7), pp.568/821-568/830.

Takahashi, Y. and Osada, T. (2014). TPM. Tokyo: Asian Productivity Organization.

Varughese, K. (2013). Total productive maintenance. Ottawa: National Library of Canada = Bibliothèquenationale du Canada.

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