From the course: Operations Foundations: Total Productive Maintenance (TPM)

TPM and restoring equipment

From the course: Operations Foundations: Total Productive Maintenance (TPM)

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TPM and restoring equipment

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- [Instructor] We always want to make sure our ultimate goal is to restore equipment to prime operating conditions. Equipment needs to be cleaned up and ready for improved operation, as if it were a brand new piece of equipment. The two key TPM concepts introduced in the restoring equipment phase are 5S + 1, where we ensure a clean and organized environment using sort, set in order, shine, standardize, and sustain, with the plus one, meaning safety. And then autonomous maintenance. It's important to initiate 5S + 1 and then autonomous maintenance, not the other way around. Always start deploying TPM after 5S + 1 is implemented in the target area. At a minimum, the steps of sort, set in order, and shine should be fully operational, including the following: tasks being documented in Standard Operating Procedures. Team leader daily assessments should be included in Leader Standard Work. Countermeasures should also be included into the Daily Tiered Accountability process. Periodic assessments and progress tracking should occur while showing that leadership Gemba walks where the work actually occurs are an integral part of the business. Next step is autonomous maintenance for the equipment, which includes the following steps. Clean and inspect. Does it look funny, smell funny? Hopefully not taste funny. Eliminate sources of dirt and contamination, and improve access. Clean all crevices and hard-to-reach areas. Establish cleaning and lubrication standards. Have standards of when you will clean and how it is known what has been done to clean. Train operators to conduct general equipment inspections. This can be done through simple visual cues of what to look for and how. Conduct autonomous inspections. Inspect all areas of products, looking for errors, or loose fittings. Implement visual maintenance management. Make things as visual to see problems as looking at a traffic light. Everyone knows that red means stop and green means go. Achieve sustainable continuous improvement. We continually improve every single day, no matter what we are doing. Using 5S + 1 and autonomous maintenance to restore equipment is like making it brand new again. We're able to take existing equipment and clean it, replace parts, or update technical requirements so it works like it's right out of the box.

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