Equipment functioning at peak levels… Happy workers… Clean environment… Less waste… Decrease in maintenance and repair spending…
These are some of the many benefits enjoyed by a facility buzzing along under the auspices of TPM.
Adhering to TPM practices is timesaving; rather than needing hours to weeks for costly repairs or replacements, workers expend some time daily to ensure proper functioning of their respective machines and areas. As they become more familiar with the maintenance and operational requirements of their equipment, workers can then transition from preventive maintenance into predictive maintenance, wherein they are so familiar with the inner workings and demands of the machine that some upgrades or replacement can be anticipated and performed before anything goes wrong. This mode is very cost-effective; generally with predictive maintenance, there will be no exorbitant emergency costs. Rather, those tools and supplies needed for daily essential upkeep, as well as foreseen upgrades, will be consistently stocked. You're controlling your costs; you're predicting your maintenance needs, both short- and long-term.
Many experts agree that with full implementation, TPM will begin decreasing facility costs (equipment and time related) by as much as 20 percent within the first two years.
Ultimately, with TPM adopted, equipment effectiveness will be maximized. With the necessary upgrades, cleaning, and maintenance performed regularly, fewer costly breakdowns will occur. Meticulous upkeep of machines will increase their functional life span. And with less repair- and maintenance-related downtime, productivity and subsequently profitability will increase.
Not implementing TPM can be far more costly. Expenses come in the form of equipment downtime for repairs, lost production opportunity, productivity losses, and costly emergency repairs, maintenance, or replacements.
Drawbacks? Not many. Occasionally, the cost to buy additional cleaning supplies and equipment may grow.
A common problem found by TPM followers is the environmental impact the new routine can have. Modifications may be made that result in a more demanding cleanup regimen. Launching a rigorous maintenance routine will inevitably shake things up a bit. More cleaning agents will be required, which means more stock room will be needed. Also, empty cleaning bottles, used rags and paper products, etc., can contribute to a waste problem. Cleaning supplies can contain some harmful solvents of chemicals that may have unpleasant odors or bring about an unhealthy breathing environment.
With equipment issues at bay, companies can then more largely focus time and efforts on quality assurance and customer satisfaction. Utilizing TPM techniques, facilities can achieve an optimum life-cycle of production equipment and maximized plant effectiveness. Companies can then more largely focus time and efforts on quality assurance and customer satisfaction.