TPM Reliability Partnership

TPM focuses your entire organization on being responsible for reliability and reducing maintenance events. 

OVER 80% OF REACTIVE MAINTENANCE CALLS ARE PREVENTABLE

Most breakdowns show signs of an impending failure. Without exception, early work discovery through an engaged organization where everyone is responsible for reliability is the single factor in breaking the pattern of reactive maintenance. 

 

 

The call to maintenance will come either way; before or at the point of failure. Why not simply move the communication further up the failure curve and everything changes. 

 

Reactive Maintenance

The only difference between a reactive and corrective call – is “WHEN”. The job scope is the same in either case but when the work is done impacts mean time to repair – MTTR. In addition, the impact of unscheduled interruption to operations and OEE (overall equipment effectiveness) scores. As front line defense, operations are at the equipment every day and given the proper tools and process, can communicate problems which are then planned and scheduled under our control.  

 

Topics & Tools of Focus in the TPM Toolkit
  • Cultural Readiness > Mindsets

  • Operational Ownership > Autonomous Care

  • Work Identification > Work Request Process

  • TPM Kaizen > Asset restoration Kaizen

  • Work Identification > Work Request Process

  • Operational Ownership > Change Overs

  • TPM Kaizen > 5S

 Learn about a TPM Reliability Partnership!

While the TPM process has been around for over 25 years many are just getting to the point of readiness. TPM is much more than just early work discovery; it is a cultural approach towards total equipment management where everyone in the organization works together, similar to the mindset we have to safety. This engagement breaks down barriers where “you run it – we fix it”

is considered normal.

 

Our Streamlined Nakajima’s 12-step TPM Process Achieves Quantifiable Change
  • Reduction in unplanned downtime

  • Reduced mean time to repair – MTTR

  • Pride of ownership

  • Operations and maintenance partnership

  • Failure prevention and countermeasures

  • Set-up time reduction

  • Quality assurance

 

Cultural Experiment

Consider this experiment if it were conducted in your organization: What if you offered everyone in the site $20 if they could find a single problem on their equipment. What do you think the answer would be? If you believe they could find a problem, the bigger question is “Why are those problems not communicated already”?

 

These problems are also not calculated in your overall backlog of maintenance work even though they are defects. They just haven’t made it to a work order.

 

Cause & Affect

In most cases, current craft productivity dealing with an existing backlog uncovers a bigger problem…What would we do with the influx of work requests? The answer is to work in both work discoveries (TPM on the supply side) in conjunction with craft productivity (Workflow Optimization on the consumption side). In this way you can create balance to work your way out of this problem.

 

SEAM Group’s approach will assist in every aspect of TPM deployment
  • Site readiness assessment

  • Launch

  • Promotional campaign

  • Steering team development & support

  • Project management

  • Autonomous teams

  • Metrics

  • Daily upkeep

  • Work request process

  • Story boards

  • Single point lessons

  • Training & coaching

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