TPM, A new paradigm in manufacturing
Continued
from Aug. 21 2009
The purpose of these activities is to achieve quickly and
economically products that are easy to make and equipment that is easy
to use. TPM in Administrative and Support departments play an important
role in backing up production activities.
The quality and timeliness of the information supplied by
administrative and support departments have a major impact on these
activities. TPM program in such a department must aim to create an
“information factory” and apply process analysis to streamline the
information flow. Initially, TPM addresses manufacturing and a little
bit on supporting administration functions within manufacturing.
In the second stage TPM addresses supply chain issues. Finally TPM in
sales addresses all the losses in the distribution network and takes the
organizations to World-Class. TPM is a step by step approach and it
takes about seven years to achieve World-Class status.
Today, most of organizations are in a hurry to reach World-Class and,
they are reluctant to choose TPM as a road map in view of its step by
step approach and prolonged process.
The Toyota Production System (TPS) is closely linked to TPM. TPS is
down to earth elimination of waste. Just in Time (JIT) delivery and
“Jidoka” (Automation) are two major concepts incorporated into the
Toyota Production System. For JIT system to function properly, defective
products should be kept to the minimum, aiming at a zero level of
processed product inventory. The automation to function properly, the
equipment failure rate should also be kept to the zero level. TPM is
essential in achieving the zero level of defective products, processed
inventory and equipment failures.
Any organization loves to implement TPS because it brings more profit
to the business quickly through elimination of seven wastes. (Especially
through inventory reduction). How can we reduce inventory without
reliable equipment and skilled workforce? TPM addresses both.
My advise to lean implementers is, to start their transformation
journey with 5S and TPM because you need reliable equipment and a highly
disciplined set of employees who can take your organization to
World-Class. It is very appropriate that the Jasteca Institute of
Management has launched a TPM practitioner certificate program for the
benefit of Sri Lankan industries.
Thilak Pushpakumara
(JIPM accredited TPM instructor), CEO/Lean Management Consultant;
Institute of Lean Management (Pvt) Ltd, Former Plant Manager, Unilever,
Sri Lanka, Former General Manager, Productivity Improvement and Training
and Development, Loadstar Pvt, Limited |
