TPM which stands for Total productive Maintenance is a
management concept that focuses on Bottoms-up approach and increased
participation of people at all levels in decision making. SKAPS embarked on the
journey of TPM in 2015 with primarily two goals in mind: Stabilization and
Involvement of Everyone. Being the TPM Manager at SKAPS I can tell you this
that the journey has been a challenging one but at the same time the results
have been rewarding. TPM, unlike other management concepts like TQM, Six-Sigma,
lean etc. gives utmost importance to empowering the floor workers and urges
management to spend more time on the floor than on the computer and this is
what creates the difference. I am not saying that other management concepts are
inferior to TPM just because I am implementing it in SKAPS but according to me
it has an edge over other concepts if implemented judiciously. TPM says that
machines are the heart of any manufacturing firm and if you take care of the
machines you take care of the business.
In this blog series specially dedicated to TPM I’ll be
sharing various concepts of TPM, challenges faced while implementing
TPM, TPM journey at SKAPS, some interesting stories from the floor and much
more. You can comment, like, share your ideas about what I have to say. I am
not an expert but discussions emerging from your honest feedback will lead to
new and better ideas which will help us all.
In my previous blog I talked about the concept of 5S and how it can be used as an effective management tool. In this blog, I’ll be talking about Overall Equipment Efficiency (OEE) which forms the key measuring indicator of the entire TPM activity in an organization. OEE tells you about your equipment’s efficiency by determining the losses associated with it. According to TPM, there are 16 major losses in any manufacturing unit as mentioned below: Losses Category 1 Breakdown Loss Losses that impede equipment efficiency 2 Setup & Adjustment Loss 3 Cutting Blade Loss 4 Start-up loss 5 Minor Stoppage/Idling Loss 6 Speed Loss 7 Defect/Rework Loss 8 Scheduled Downtime loss or Planned Downtime 9 Management Loss Losses that impede human work efficiency 10 Operation Motion Loss 11 Line Organization Loss 1...
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