Equipment reliability is one of the key successes of the Toyota Production System. The ability of running production at the correct quality and quantity is essential to meeting customer needs.
The goal of a Total Productive Maintenance program is to enhance autonomous (functioning independently without control by others) maintenance activities along with supporting the team concept within areas.
Lean Masters formulates a Total Productive Maintenance Program that is team based maintenance designed to ensure that the production equipment is:
- Always available — zero breakdowns
- Capable of making the required volume with zero defects.
- Able to meet Takt Time (making the product to the customer demand rate).
TPM also improves worker morale due to improved equipment reliability through getting everybody involved on constant maintenance improvement.
Reduction of Waste (Muda)
Kaizen (Rapid Continuous Improvement Workshop)
Standard Work Instructions
5S or Visual Management
Key Performance Indicators (KPI)
Total Productive Maintenance (TPM)
Quick Changeover / SMED
Root Cause Problem Solving
Lean Roles and Responsibilities
Value Stream Mapping
Error Proofing (Poka-Yoke)
Team Leaders & Work Teams