Increase your TPM with scheduling

If your maintenance team has the opportunity to be 100% efficient and productive wouldn’t you take it? It’s something that seems superfluous, but it remains the ultimate goal of any organization that decides to implement Total Productive Maintenance.

While TPM may sound elusive, it all depends on how you plan for it.  The old adage really does ring true: If you don’t plan, you plan to fail.

That’s why our customer Quaker Oats uses our scheduling module for planned downtime.  This allows them to reach a significant increase of 27% schedule utilization across their plant.  With more defined downtime, their TPM has greatly increased.

But before we get into more about how scheduling can aid TPM, lets learn a little more about

TPM is a unique method of maintenance that involves machine operators in the maintenance process of the equipment they operate. It is applicable across several industries, however it is most commonly used in the manufacturing sector due to its radical and unique approach to maintenance. 

In manufacturing, TPM primarily focuses on equipment effectiveness, which aims to determine the percentage of production time that is productive.  The goal is to track progress towards “perfect production”, with scores ranging from as low as 40% for inefficient systems, to 100% for perfect systems.

What are the goals of TPM?

TPM is based upon achieving certain goals such as:

  • A proactive (see proactive vs. reactive) approach to maintenance with shared accountability for equipment care
  • Employees at all levels in the company are involved in the maintenance process leading to decreased downtime
  • No equipment defects and zero downtime
  • Achieving zero accident levels and creating a safer work environment
  • Low waste in the production process
  • Improving product quality

What are the benefits of TPM?

Businesses that strive for perfection and employ TPM can reap the following benefits:

  • Team members are empowered and encouraged to maintain their machines giving them a sense of “ownership”
  • Minor maintenance issues are brought to attention and fixed faster, without waiting for the assessment of the maintenance technicians
  • Improved productivity due to fewer breakdowns and stops
  • Improved quality and customer satisfaction
  • Lower manufacturing cost
  • Fewer accidents in the work process

How scheduling impacted TPM for Quaker

In addition to substantial savings, the scheduling module has fueled many opportunities for insight.  Managers are able to see how one team is using the schedule successfully or look upon the schedule to examine and pinpoint areas that could use improvement.  “Using the scheduling module actually gives us the ability to go in and look at what people are doing,” explains Brandon, “Before we didn’t know, and now we can actually use this information and in some cases include it in our KPIs.”  

How can CMMS help with Total Productive Maintenance?

A quality CMMS system can aid in implementing Total Productive Maintenance in many ways.  It allows for more autonomous maintenance, more planned maintenance, focused improvement, better education and training, and improved quality management.

One of the major ways to increase TPM is by investing in a CMMS software that helps keep everything on schedule.  A good CMMS will not only increase Total Productive Maintenance, but will help you target other KPIs as well.  For more insight about how Quaker improved their TPM with CHAMPS and their scheduling module, click here. To learn more about how CMMS can help with your scheduled maintenance, call us at (352)-795-2362 or schedule a demo today!

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