Drive Total Productive Maintenance with Digitalization

TPM and Its Relevance for Manufacturing Organizations

Total Productive Maintenance or TPM is an approach for the maintenance of machinery and assets in manufacturing organizations with a holistic view and participation from all departments within the organization, focusing on reducing waste and implementing lean principles. Often maintenance of machinery in manufacturing factories is considered the responsibility of only the maintenance department, which results in mishandling of machines, avoiding daily checks and small maintenance, and resulting in bigger maintenance problems and major breakdowns, hence loss of productive time and affecting quality of products manufactured. 

The concept of TPM was developed by Seiichi Nakajima in Japan between 1950 and 1970, formalized and benchmarked as an internationally accepted standard by the Japan Institute of Plant Maintenance (JIPM) around 1971, which intends to disseminate the responsibility of maintenance and machine performance, improving employee engagement and teamwork within the management, engineering, maintenance, and operations or production departments in the organization.

The key objectives of TPM are as below:

• Maximize Equipment Effectiveness
• Eliminating Equipment Losses
• Improving Maintenance Reliability
• Engaging Empowering Employees
• Enhancing Product Quality
• Optimizing Maintenance Practices
• Promoting Cross-Functional Collaboration
• Building a Culture of Improvement
• Achieving Operational Excellence

The main focus of TPM is maximizing equipment effectiveness and reducing losses to optimize overall operational efficiency. It also enables data-driven decision-making with an approach of continuous and focussed improvements which ultimately is realized by cross-collaboration across teams and departments.

It is said that the TPM mindset can be compared to how a baby is treated by its parents and doctors. Consider the machine is like a baby and the line or machine operators are the parents, who take care of its daily needs and check for its well-being continuously and can address and resolve minor issues regularly. But when there is an indication of a major issue or a periodic check-up is needed like the parents taking the baby to a doctor who specializes in specific issues and can treat serious conditions, the maintenance team is involved to do the major maintenance activities. The point here is that the production or line operator of the machines should take care of the machine’s performance and daily activities such as cleaning, lubrication, adjustments, etc. which ensures the well-being of the machine and ensures it runs on high performance.

Eight Pillars of TPM

TPM mandates eight types of activities which are often called as eight pillars of TPM as below:

Autonomous Maintenance (Jishu-Hozen) enforces that the operators of the machines are trained and empowered to perform routine and proactive maintenance tasks, such as cleaning, inspection, lubrication, and minor repairs to avoid breakdowns.

Planned Maintenance (PM) emphasizes the implementation of planned maintenance activities to minimize unplanned downtime. To avoid equipment breakdowns and unplanned downtime, it’s important to schedule maintenance tasks.

Focused Improvement (Kobetsu-Kaizen) focuses on continuous improvement of equipment, processes, and systems. All operators and technical personnel are encouraged to work together with the common goal of achieving regular improvements in equipment operation.

Quality Maintenance (Hinshitsu-Hozen) emphasizes maintaining and improving product quality by addressing defects, reducing variation, and implementing measures to ensure reliable and consistent product output.

Employee Training & Development (ET&D) recognizes the importance of providing appropriate training and skills development to employees involved in equipment maintenance and operation.

Employee Safety & Health (ES&H) incorporates safety and health considerations in equipment maintenance and operation and promotes a safe working environment.

Early Management (EM) aims to ensure that new equipment or processes are designed and introduced with reliability and maintainability in perspective.

Administrative TPM (Office TPM) extends the principles of TPM to the office or administrative areas.

Challenges in TPM using Non-Digitalized and Manual Methods

Traditional TPM methods using manual and non-digitalized approaches may face several challenges that may hinder their effectiveness. Here are some common challenges and pitfalls associated with non-digital and traditional TPM implementation approaches:

• Manual Data Collection and Analysis: Relies on manual data collection methods, such as paper-based forms or spreadsheets. This process is time-consuming, prone to errors, and lacks real-time visibility. Manual data analysis can also be subjective and inconsistent, limiting the accuracy and efficiency of TPM decision-making.
• Limited Equipment Monitoring: May lack comprehensive equipment monitoring capabilities. Monitoring equipment conditions and performance manually or infrequently can result in missed opportunities to detect early signs of degradation or failure. Without real-time visibility into equipment status, organizations may struggle to implement preventive maintenance effectively.
• Reactive Maintenance Approach: Often reactive in nature, with maintenance activities primarily initiated in response to equipment failures or breakdowns. This reactive approach leads to unplanned downtime, increased maintenance costs, and decreased overall equipment effectiveness. The focus on reactive maintenance prevents organizations from optimizing maintenance schedules and adopting proactive strategies.
• Siloed Information and Communication: May suffer from information silos and communication gaps. Relevant data and insights on equipment performance, maintenance history, and process parameters may be dispersed across different departments or individuals. Limited sharing of information can impede collaborative decision-making and hinder the ability to identify and address issues holistically.
• Lack of Data-Driven Decision-Making: Lack of use of data-driven decision-making processes. Decision-making is often based on subjective observations or historical practices rather than quantitative analysis. Without access to real-time and accurate data, organizations may struggle to identify performance bottlenecks, optimize maintenance schedules, or allocate resources effectively.
• Insufficient Training and Skill Development: May not prioritize training and skill development for maintenance personnel. With rapid advancements in technology and evolving equipment requirements, it is crucial to equip maintenance teams with up-to-date skills and knowledge. Insufficient training can limit the ability to effectively utilize digital tools, analyze data, and implement advanced maintenance strategies.
• Resistance to Change and Lack of Employee Engagement: Can face resistance to change, especially if they disrupt established routines or require new ways of working. Lack of employee engagement and participation can hinder the successful implementation and sustainability of TPM initiatives. The success of TPM relies on active involvement and ownership from all levels of the organization.

Overcoming these challenges requires organizations to embrace digitalization, leverage technology tools, and adopt a proactive approach to maintenance. Implementing digital TPM solutions can address these challenges by automating data collection, enabling real-time monitoring, facilitating data-driven decision-making, promoting cross-functional collaboration, and fostering a culture of continuous improvement and employee engagement.

Enabling Digitalization Across Eight Pillars of TPM

Digital technologies can be a great enabler to realize TPM practices effectively and optimally and can help drive adoption across each pillar as below.

Autonomous Maintenance

Digital technologies can enhance autonomous maintenance by providing tools and resources to operators, enabling them to perform their maintenance tasks more effectively.

•      Digital Checklists: Operators can use digital checklists and mobile applications to guide them through maintenance procedures, ensuring that all necessary tasks are completed accurately and efficiently.

•      Augmented Reality (AR): AR technology can provide real-time guidance and instructions to operators during equipment maintenance and troubleshooting. It overlays digital information onto the physical equipment, helping operators identify parts, access maintenance procedures, and resolve issues more effectively.

Planned Maintenance

Digital technologies can optimize planned maintenance activities by providing real-time data, automated scheduling, and improved visibility into maintenance processes.

•      Computerized Maintenance Management Systems (CMMS): CMMS software enables the planning, scheduling, and tracking of maintenance activities. It centralizes maintenance data, automates work orders, and provides notifications for preventive maintenance tasks.

•      Condition Monitoring: Integration of sensors and IoT devices allows real-time monitoring of equipment conditions, such as vibration, temperature, and pressure. This data helps identify potential issues early, enabling proactive maintenance planning and reducing unplanned downtime.

Quality Maintenance

Digital technologies enhance quality maintenance by providing real-time monitoring, data analysis, and process control capabilities.

•      Statistical Process Control (SPC): SPC software enables real-time monitoring and analysis of process data. It helps identify variations, trends, and potential quality issues, allowing for timely corrective actions to maintain product quality.

•      Machine Vision Systems: Machine vision technology can be used to inspect and detect defects in products during production. It enhances quality control by ensuring accurate and consistent product specifications, reducing the need for manual inspections.

•      Equipment Calibration: Equipment calibration is an important task to ensure the machine is adjusted and configured to provide optimum output which ensures quality production. Tracking the equipment calibration schedule and capturing the inspection result digitally ensures the calibration is done in time.

Focused Improvement

Digital technologies enhance Focused Improvement providing tools and capabilities to identify, analyze, and address equipment-related issues and improvement opportunities.

•      OEE, Loss Data Collection, and Analysis: Digital technologies enable efficient and automated data collection from various sources, such as sensors, equipment monitoring systems, and production databases. This data can be analyzed using advanced analytics, machine learning, and artificial intelligence techniques to identify patterns, anomalies, and potential improvement areas. Digital tools provide the ability to perform root cause analysis, Pareto analysis, and other data-driven techniques to prioritize improvement efforts.

Employee Training and Education

Digital technologies improve training and education by providing interactive and immersive learning experiences.

•      Virtual Reality (VR): VR technology creates immersive training environments where maintenance personnel can simulate equipment operations, practice maintenance tasks, and enhance their skills and knowledge in a safe and controlled virtual setting.

•      GenAI Chatbot: GenAI Chatbot can be trained with SOP, manuals, and documents related to the machines and processes, and the users can query in natural language and get the relevant information for their work.

•      E-Learning Platforms: Online learning platforms and digital training modules provide flexible and accessible training content, allowing maintenance teams to learn at their own pace and access resources anytime, anywhere.

Safety, Health and Environment

Digital technologies improve safety, health, and environmental practices by providing real-time monitoring, communication, and risk assessment capabilities.

•      Internet of Things (IoT) for Safety Monitoring: IoT sensors can be used to monitor environmental conditions, worker safety, and equipment safety parameters in real-time. They provide alerts and notifications to prevent accidents and ensure a safe working environment. Digitally tracking the incidents and analyzing them helps in identifying the key incident causes and preventing the same.

•      Wearable Technologies: Wearable devices, such as smart helmets or smart vests, equipped with sensors and communication capabilities can enhance worker safety by providing real-time safety notifications, location tracking, and risk assessment.

•      Permit to Work and Job Safety Analysis: Digitally tracking the work permits and job safety analysis helps to ensure no work is done without the correct authorization and safety prerequisites.

Early Equipment Management

Digital technologies enhance early equipment management by enabling advanced design, simulation, and evaluation of equipment performance.

•      Computer-Aided Design (CAD): CAD software facilitates the digital design and modeling of equipment. It allows for early evaluation of equipment reliability, maintainability, and operability during the design phase, minimizing potential issues and optimizing equipment performance.

•      Simulation and Digital Twin: Simulation tools and digital twins create virtual replicas of equipment, enabling organizations to simulate equipment behavior, predict performance, and optimize design parameters before physical implementation. This allows for more accurate and efficient equipment development.

Administrative or Office TPM

Digital technologies enhance administrative or office TPM by enabling advanced design, simulation, and evaluation of equipment performance.

•      Inventory Tracking: Digital solutions and technologies help in tracking the inventory of materials used and produced by the organization using IoT-based sensors, and RFID and maintaining them in digital applications for easy visibility and planning.

•      Demand Forecasting and Supply Chain Optimization: Digital systems help in tracking the different elements of the supply chain such as freight, material suppliers, and warehouses, and optimize the planning across them to enable a more reliable and better supply chain.

Digital Technologies to Enable TPM

Below are some examples of how digital technologies can enhance TPM practices in general. The specific digital tools and technologies adopted may vary depending on the organization’s requirements and the level of digitization they seek to achieve in their TPM implementation.

•      Data Analytics and Predictive Maintenance: Advanced analytics and machine learning algorithms can be applied to maintenance data to identify patterns, predict failure modes, and recommend optimal maintenance strategies.

•      Digital Dashboards and Reporting Tools: Utilization of digital dashboards and reporting tools for visualizing and communicating key performance indicators, maintenance metrics, and equipment effectiveness in real time.

•      Performance Visualization and Reporting: Digital tools offer real-time monitoring, visualization, and reporting capabilities, allowing organizations to track key performance indicators (KPIs) related to equipment effectiveness, downtime, quality, and productivity. Digital dashboards and reporting tools provide stakeholders with clear visibility into performance trends, allowing for timely decision-making and action planning. This promotes a culture of transparency and accountability for improvement initiatives.

•      Collaboration and Knowledge Sharing: Digital platforms, collaboration tools, and knowledge management systems facilitate cross-functional collaboration and knowledge sharing within the organization. Teams can share improvement ideas, best practices, and lessons learned using digital communication channels and collaboration platforms. This fosters a culture of continuous improvement and enables the dissemination of successful improvement initiatives across different departments and locations.

•      Continuous Improvement Software: Digital continuous improvement software enables the systematic management of improvement projects, actions, and initiatives. These tools provide features like project tracking, task management, progress monitoring, and performance measurement. They streamline the improvement process, enable data-driven decision-making, and ensure the successful implementation and tracking of improvement initiatives.

•      Mobile Applications: Mobile applications and devices provide on-the-go access to TPM-related information, data collection forms, and improvement tools. Maintenance personnel and operators can use mobile devices to report issues, capture improvement ideas, and access relevant information and resources. Mobile apps enable real-time data collection, collaboration, and decision-making, enhancing the efficiency and effectiveness of improvement activities.

•      Digital Gemba Walks: Digital technologies enable virtual Gemba walks, where managers and improvement teams can remotely observe and assess equipment conditions, processes, and performance. Digital tools such as video streaming, remote monitoring, and augmented reality can be utilized to virtually analyze and discuss improvement opportunities with operators and maintenance personnel on the shop floor, irrespective of physical location.

Conclusion

As explained above TPM provides a holistic approach for asset management and improving its performance by engaging teams for cross-collaboration and adopting practices to ensure responsiveness and continuous improvements, thereby optimizing effectiveness and improving quality. Digital technologies play a major enabler in achieving the same in various ways to enable tracking, visibility, and automation and make the asset management process more seamless and intelligent, which in turn ensures better machine uptime and productivity increase and better product quality.

If you want to know more about how you can adopt TPM practices for your maintenance operations using digital solutions check out Incture Cherrywork Intelligent Maintenance & Operations (IMO) solution, which provides a unified platform to adopt TPM with web and mobile applications integrated with your SAP S/4HANA or connect with me.