You have a process for ensuring equipment is available for production when required
To meet demanding customer delivery schedules, manufacturing must have equipment available for production when required. Considerable cash can be released by removing inventories from supply chains; however, this makes them less tolerant to unplanned events that disrupt production. This means equipment must be subject to new maintenance regimes  
Key Issues
·         Traditional. reactive maintenance routines based on fixing a problem once equipment has developed a fault are no longer viable
·         The demands of “just in time” manufacturing made the Japanese adopt a new approach to the maintenance, repair and servicing of equipment called Total Productive Maintenance (TPM)
·         TPM in overview:
o      Maintenance should be considered at three levels:
routine checks being carried out by your machine operators,
planned maintenance by your central in-house team
preventive maintenance undertaken by specialists
o      Risk assessments should be compiled to predict possible breakdowns, identifying machine recovery modes and alternative production routes
o      Your people should be trained to recognise the initial signs of malfunction
o      On key equipment, consider the use of detection devices to provide an early warning of impending problems
·         Cost effective, planned maintenance routines require:
o     Records of machine breakdowns to be established and updated, noting performance characteristics and likely failure modes
o     Servicing and overhaul plans for families of machines
o     Machines to be regularly cleaned, all bolts tightened, and any obvious faults immediately rectified
o     Planned maintenance time built into production schedules
o     Regular training provided for maintenance teams to ensure consistently good workmanship and updates for any new technologies
o     Maintenance costs closely monitored and allocated to machines
·         Clear documentation of maintenance procedures is needed for:
o     Routine daily and weekly checks
o     Servicing - refurbishing perishable items / fluids
o     Planned maintenance - identifying tasks, time intervals and who will be responsible for undertaking the work
o     Preventive maintenance to ensure key equipment has any necessary upgrades and is capable of performing to specification
o     Diagnosis of possible faults and instructions for rectification
o     Ways for checking process capability, including appropriate time intervals
Factors for Success      
Factors to  Avoid
1.     Your production managers champion the need for effective maintenance
2.     Most of your maintenance time and money is invested in preventing unplanned events
1.     Your Maintenance people only attending to machines when they break down
2.     Allowing untrained technicians to work on complex machines and equipment 
Who does this apply to?
Senior management and people responsible for maintenance
Realisable Benefits
Increased productivity, fewer unplanned emergencies, longer machine life


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