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

Guides:

Logistics co-ordinationLogistics co-ordination

Logistics co-ordination

Uninterrupted material flowUninterrupted material flow

Uninterrupted material flow

Responding to changes in volumes and product mixResponding to changes in volumes and product mix

Responding to changes in volumes and product mix

Make versus buyMake versus buy

Make versus buy

The supplier approval processThe supplier approval process

The supplier approval process

Monitoring supplier performanceMonitoring supplier performance

Monitoring supplier performance

Sharing information with suppliersSharing information with suppliers

Sharing information with suppliers

Managing inventory throughout the supply chainManaging inventory throughout the supply chain

Managing inventory throughout the supply chain

Improving the delivery performance of suppliersImproving the delivery performance of suppliers

Improving the delivery performance of suppliers

Material flow and the factoryMaterial flow and the factory

Material flow and the factory

Production scheduling processProduction scheduling process

Production scheduling process

Calculating production capacityCalculating production capacity

Calculating production capacity

Visual managementVisual management

Visual management

Health and safetyHealth and safety

Health and safety

HousekeepingHousekeeping

Housekeeping

WasteWaste

Waste

Ensuring equipment is availableEnsuring equipment is available

Ensuring equipment is available

ChangeoversChangeovers

Changeovers

BottlenecksBottlenecks

Bottlenecks

Consistent manufacturingConsistent manufacturing

Consistent manufacturing